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.

A casting mold having at least one cavity for manufacturing at least one cast article, in which at least some areas of a casting surface of the casting mold delimiting the cavity have a surface texture. The surface texture has multiple elementary cells, wherein each elementary cell has a structure that projects and/or is recessed with respect to the casting surface and ends within the applicable elementary cell. In addition, a cast article produced by the casting mold is provided.

A casting mold having at least one cavity for manufacturing at least one cast article, in which at least some areas of a casting surface of the casting mold delimiting the cavity have a surface texture. The surface texture has multiple elementary cells, wherein each elementary cell has a structure that projects and/or is recessed with respect to the casting surface and ends within the applicable elementary cell. In addition, a cast article produced by the casting mold is provided.

A method and casting core for forming a landing for welding a baffle inserted into an airfoil are disclosed, wherein the baffle landing of the blade or vane is formed in investment casting by the casting core rather than by wax, reducing tolerances and variability in the location of the baffle inserted into the cooling cavity of airfoil when the baffle is welded to the baffle landing.

A method and casting core for forming a landing for welding a baffle inserted into an airfoil are disclosed, wherein the baffle landing of the blade or vane is formed in investment casting by the casting core rather than by wax, reducing tolerances and variability in the location of the baffle inserted into the cooling cavity of airfoil when the baffle is welded to the baffle landing.

A manufacturing method uses layered slabs to create a final pattern for a mold or for creating the mold itself. The method includes: preparing a desired number of slabs including a first slab and a second slab; machining the first slab; machining the second slab; and after the second slab is coupled to the first slab, repeating the machining step for each additional slab included in the desired number of slabs to form the final pattern or mold.

A manufacturing method uses layered slabs to create a final pattern for a mold or for creating the mold itself. The method includes: preparing a desired number of slabs including a first slab and a second slab; machining the first slab; machining the second slab; and after the second slab is coupled to the first slab, repeating the machining step for each additional slab included in the desired number of slabs to form the final pattern or mold.

A method of manufacturing for finishing ceramic core flash. Locating a first hole on a ceramic core by a laser sensor on a robot. Probing for a center of the first hole by a force-torque sensor on the robot. Scanning for an axial position of a second hole on the ceramic core. Scanning for a third hole on the ceramic core. Probing for a center of the third hole. Determining axial and radial scale factors based on the first hole location and the third hole location. Uploading the axial and radial scale factors to the robot Multiplying the X component position by the axial scale factor and the Z component position by the radial scale factor in an array format. Cutting a designated scaled location along the ceramic core to remove flash. Repeating process for additional scaled locations along the ceramic core.

A method of manufacturing for finishing ceramic core flash. Locating a first hole on a ceramic core by a laser sensor on a robot. Probing for a center of the first hole by a force-torque sensor on the robot. Scanning for an axial position of a second hole on the ceramic core. Scanning for a third hole on the ceramic core. Probing for a center of the third hole. Determining axial and radial scale factors based on the first hole location and the third hole location. Uploading the axial and radial scale factors to the robot Multiplying the X component position by the axial scale factor and the Z component position by the radial scale factor in an array format. Cutting a designated scaled location along the ceramic core to remove flash. Repeating process for additional scaled locations along the ceramic core.