Methods for forming ceramic cores are disclosed. A ceramic core formed using the method of the present application includes a silica depletion zone encapsulating an inner zone. The inner zone includes mullite and the silica depletion zone includes alumina. The method includes heat-treating a ceramic body in a non-oxidizing atmospheric condition for an effective temperature and time combination at a pressure less than 10.sup.2 atmosphere to form the silica depletion zone at a surface of the ceramic core.

Methods for forming ceramic cores are disclosed. A ceramic core formed using the method of the present application includes a silica depletion zone encapsulating an inner zone. The inner zone includes mullite and the silica depletion zone includes alumina. The method includes heat-treating a ceramic body in a non-oxidizing atmospheric condition for an effective temperature and time combination at a pressure less than 10.sup.2 atmosphere to form the silica depletion zone at a surface of the ceramic core.

Systems and methods are described for constructing insulated concrete forms and their skeletons, A mold assembly is discussed for molding insulated concrete forms and has an outer housing; first and second mold lids; first and second entrance doors; first and second pluralities of downward oriented extensions, each of the first and second pluralities of downward oriented extensions being movable between a retracted position and an inserted position, to define first and second mold cavities; and fill guns oriented for injecting insulating polymeric material into the first and second mold cavities. The systems and methods may mold insulated panels on both sides of an insulated concrete form skeleton, and may be used to make forms of any length.

Systems and methods are described for constructing insulated concrete forms and their skeletons, A mold assembly is discussed for molding insulated concrete forms and has an outer housing; first and second mold lids; first and second entrance doors; first and second pluralities of downward oriented extensions, each of the first and second pluralities of downward oriented extensions being movable between a retracted position and an inserted position, to define first and second mold cavities; and fill guns oriented for injecting insulating polymeric material into the first and second mold cavities. The systems and methods may mold insulated panels on both sides of an insulated concrete form skeleton, and may be used to make forms of any length.

A method for making a ceramic heat sink is provided. In the first step of the method, a mixed material of nitrite-based ceramic powder, titanium powder and inorganic resin is prepared. The mixed material is then molded into a ceramic blank with a mold coated with titanium. Thereafter, the ceramic blank may be sintered to form the ceramic heat sink. Since the mixture and the mold both contain a common material of titanium, the molded ceramic blank can be easily removed from the mold in its integrity.

A method for making a ceramic heat sink is provided. In the first step of the method, a mixed material of nitrite-based ceramic powder, titanium powder and inorganic resin is prepared. The mixed material is then molded into a ceramic blank with a mold coated with titanium. Thereafter, the ceramic blank may be sintered to form the ceramic heat sink. Since the mixture and the mold both contain a common material of titanium, the molded ceramic blank can be easily removed from the mold in its integrity.

Various embodiments of the present disclosure provide an additive manufacturing method. The method includes forming a first layer of a first ceramic material and forming a second layer of a second ceramic material. The method further includes contacting the first layer of the first ceramic material, the second layer of the second ceramic material, or both with a saturant. The method further includes heating the first layer of the first ceramic material, the second layer of the second ceramic material, or both to a temperature in a range of from about 50? C. to about 300? C. The method further includes applying pressure to the first layer of the first ceramic material, the second layer of the second ceramic material, or both. The pressure can be in a range of from about 10 kPa to about 800 MPa. The method further includes at least partially dissolving a portion of an external surface of a ceramic particle of the first layer of the first ceramic material, the second layer of the second ceramic material, or both. The method further includes fusing a portion of the dissolved portion of the external surface of the ceramic particle to from a product having a density in a range of from about 65% to about 100% relative to a corresponding fully densified product and optionally containing no organic binder.

A method for making a ceramic heat sink is provided. In the first step of the method, a mixed material of nitrite-based ceramic powder, titanium powder and inorganic resin is prepared. The mixed material is then molded into a ceramic blank with a mold coated with titanium. Thereafter, the ceramic blank may be sintered to form the ceramic heat sink. Since the mixture and the mold both contain a common material of titanium, the molded ceramic blank can be easily removed from the mold in its integrity.

A method for making a ceramic heat sink is provided. In the first step of the method, a mixed material of nitrite-based ceramic powder, titanium powder and inorganic resin is prepared. The mixed material is then molded into a ceramic blank with a mold coated with titanium. Thereafter, the ceramic blank may be sintered to form the ceramic heat sink. Since the mixture and the mold both contain a common material of titanium, the molded ceramic blank can be easily removed from the mold in its integrity.

Methods for forming ceramic cores are disclosed. A ceramic core formed using the method of the present application includes a silica depletion zone encapsulating an inner zone. The inner zone includes mullite and the silica depletion zone includes alumina. The method includes heat-treating a ceramic body in a non-oxidizing atmospheric condition for an effective temperature and time combination at a pressure less than 10 atmosphere to form the silica depletion zone at a surface of the ceramic core.