A core forming method is provided for forming a core. The core forming method includes forming one or more mold parts of water-soluble polymer (WSP), each mold part including a bond area and a part forming area, moistening the bond areas, bonding the mold parts together with the bond areas moistened and the part forming areas aligned to form a cavity shaped as a negative of the core, injecting a slurry, which is non-reactive with the WSP, into the cavity and removing the WSP with water once the slurry is cured.

A core forming method is provided for forming a core. The core forming method includes forming one or more mold parts of water-soluble polymer (WSP), each mold part including a bond area and a part forming area, moistening the bond areas, bonding the mold parts together with the bond areas moistened and the part forming areas aligned to form a cavity shaped as a negative of the core, injecting a slurry, which is non-reactive with the WSP, into the cavity and removing the WSP with water once the slurry is cured.

Foundry casting elements and methods of forming the same, the methods including: forming an aqueous slurry including an inorganic binder precursor, shaping the slurry using a pattern, curing the shaped slurry using a low temperature solidification process to form a casting element, and removing the pattern from the casting element.

Foundry casting elements and methods of forming the same, the methods including: forming an aqueous slurry including an inorganic binder precursor, shaping the slurry using a pattern, curing the shaped slurry using a low temperature solidification process to form a casting element, and removing the pattern from the casting element.

A core forming method is provided for forming a core. The core forming method includes forming one or more mold parts of water-soluble polymer (WSP), each mold part including a bond area and a part forming area, moistening the bond areas, bonding the mold parts together with the bond areas moistened and the part forming areas aligned to form a cavity shaped as a negative of the core, injecting a slurry, which is non-reactive with the WSP, into the cavity and removing the WSP with water once the slurry is cured.

A core forming method is provided for forming a core. The core forming method includes forming one or more mold parts of water-soluble polymer (WSP), each mold part including a bond area and a part forming area, moistening the bond areas, bonding the mold parts together with the bond areas moistened and the part forming areas aligned to form a cavity shaped as a negative of the core, injecting a slurry, which is non-reactive with the WSP, into the cavity and removing the WSP with water once the slurry is cured.

3-D printed PLA material of a selected density is formed into a pattern that is configured as the outer shell of a casting form to be used in the lost foam or evaporative casting process. The purpose of 3-D printing of the PLA material is used to maintain the proper configuration of the form to facilitate casting, and reduce buildup of carbon on the surface of the casting. Because the form is essentially hollow, PLA support pieces can be used on the interior to maintain the structural integrity of the form.

3-D printed PLA material of a selected density is formed into a pattern that is configured as the outer shell of a casting form to be used in the lost foam or evaporative casting process. The purpose of 3-D printing of the PLA material is used to maintain the proper configuration of the form to facilitate casting, and reduce buildup of carbon on the surface of the casting. Because the form is essentially hollow, PLA support pieces can be used on the interior to maintain the structural integrity of the form.

The invention relates to a method for producing core sand and/or molding sand for casting purposes. A granular mineral mold base material is mixed with at least one inorganic binder and additionally an inorganic expanding additive. Water glass may be used as the binder and expandable graphite may be used as the expandable additive.

The invention relates to a method for producing core sand and/or molding sand for casting purposes. A granular mineral mold base material is mixed with at least one inorganic binder and additionally an inorganic expanding additive. Water glass may be used as the binder and expandable graphite may be used as the expandable additive.