Method and tooling for centering and shaping an irregularly shaped object

Abstract

A center-cast tool for casting a non-uniform object is provided. The center-cast tool has a body having a casting bay recessed into the top side of the body. A base forms the bottom of the casting bay. First and second apertures extend through the base and the bottom side. The second aperture intersects the first aperture in perpendicular orientation to the first aperture to form an aperture intersection. The aperture intersection forms four opposing right angles on the base at the center of the bay. The distance between adjacent right angles in the base is equal to the length of each side of the bezel of a jewelry article into which the finish machined irregular object will be set. In another embodiment, a first release hole extends through the base and the bottom side on a first side of the aperture intersection.

Claims

1. A center-cast tool for casting a non-uniform object, comprising: a body; the body having a top side and an opposite bottom side; the body having a left side and an opposite right side; a casting bay recessed into the top side of the body; a base at the bottom of the casting bay; a first aperture extending through the base and the bottom side and having a width; a second aperture extending through the base and the bottom side and having a width; the second aperture intersecting the first aperture in perpendicular orientation to form an aperture intersection; and, the aperture intersection forming four opposing right angles on the base.

2. The center-cast tool of claim 1, further comprising: the aperture intersection being centered in the bay.

3. The center-cast tool of claim 1, further comprising: the distance between all adjacent right angles at the aperture intersection are equal.

4. The center-cast tool of claim 1, further comprising: the width of the first and second apertures are equal.

5. The center-cast tool of claim 1, further comprising: a first release hole extending through the base and the bottom side on a first side of the aperture intersection.

6. The center-cast tool of claim 1, further comprising: a second release hole extending through the base and the bottom side on a second side of the aperture intersection.

7. The center-cast tool of claim 1, further comprising: a left arm extending from the left side of the body; and, a right arm extending from the right side of the body.

8. The center-cast tool of claim 1, further comprising: the first and second apertures being longitudinal in shape.

9. A method of manufacturing an irregularly shaped object, comprising: providing the center-cast tool of claim 1; attaching a transparent adhesive tape to the bottom side of the body so as to cover the first and second apertures; selecting a display side of the irregular object; positioning the irregular object over the aperture intersection such that the display side is in contact or near contact with all four of the right angles on the base; securing the display side to the adhesive tape at the aperture intersection; filling the bay with a solidifying casting material; allowing the casting material to solidify around the irregular object; and, removing the solidified casting and irregular object from the bay for further processing.

10. The method of manufacturing an irregularly shaped object of claim 9, comprising: providing a first release hole extending through the base and the bottom side on a first side of the aperture intersection; and, pressing the casting out through the first release hole.

11. The method of manufacturing an irregularly shaped object of claim 9, comprising: providing a left arm extending from the left side of the body; providing a right arm extending from the right side of the body; and, extending an elastic band between the left and right arms in tension such that the elastic band presses the irregular object against the opposing right angles of the base.

12. The method of manufacturing an irregularly shaped object of claim 9, comprising: the solid casting having a casting display side associated with the side of the casting that was in contact with the base of the bay; the solid casting having a casting off display side associated with the side opposite to the display side; the casting display side having perpendicular extensions formed where the casting material filled the first and second apertures; locating the display side in a fixture configured to receive the display side of the solid casting; and, grinding the off display side to the thickness desired for mounting in a bezel of a jewelry article.

13. The method of manufacturing an irregularly shaped object of claim 9, comprising: the solid casting having a casting display side associated with the side of the casting that was in contact with the base of the bay; the solid casting having a casting off display side associated with the side opposite to the display side; the display side having extensions formed where the casting material filled the first and second apertures; locating the off display side in a fixture configured to receive the off display side of the solid casting; and, sawing through the solid casting adjacent to the extensions of the solid casting.

14. The method of claim 9, further comprising: the irregularly shaped object being a baby tooth.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The drawings constitute a part of this specification and include exemplary embodiments to the disclosed method, which may be embodied in various forms. It is to be understood that, in some instances, various aspects of the disclosed method may be shown exaggerated, enlarged or otherwise spatially modified to facilitate an understanding of the disclosed method.

(2) FIG. 1 is a digital scan of an exfoliated deciduous tooth, uploaded to viewing software, such as a CAD system.

(3) FIG. 2 is a top isometric view of a center-cast tool illustrative various embodiments of the present disclosure.

(4) FIG. 3 is a bottom isometric view of the center-cast tool of FIG. 2.

DETAILED DESCRIPTION

(5) The following description is presented to enable any person skilled in the art to make and use the disclosed method, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the disclosed method. Thus, the disclosed method is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.

(6) FIG. 1 is a three dimensional digital n of an exfoliated deciduous tooth 1. Tooth 1 is a cuspid in this example, but the device and methods disclosed herein are equally useful for any other tooth, or any other irregularly shaped object where it is desired to preserve one natural surface as against 5 perpendicular surfaces. In this view, it is seen that there is a neck portion 2 and a facial surface 4. A display surface 6 has been selected as the facial surface 4 of this baby tooth 1.

(7) A plurality of squares 8, including 8A and 8B have been superimposed on display side 6 to demonstrate the multiplicity of options for machining tooth 1 to a size sufficient to fit inside a bezel of a selected jewelry article. However, the various squares 8 do not advise the machinist/jeweler as to which choice will provide a finish product in which the corners of the tooth 1 will match the height of the bezel into which it is mounted. It has been determined that this has a big impact on the quality of the appearance of the final product.

(8) For example, machining along square 8A may result in one or more corners of the surface of display side 6 being lower or higher than the other corners. In this instance, machining at 8B provides a superior result.

(9) FIG. 2 is a top isometric view of a center-cast tool illustrating various embodiments of the present disclosure. FIG. 3 is a bottom isometric view of the center-cast tool of FIG. 2. The description below refers to both FIGS. 2 and 3.

(10) A center-cast tool 10 is provided. Center-cast tool 10 has a body 12 having a top side 14 and an opposite bottom side 16 (see FIG. 3). Center-cast tool 10 has a left side 18 and opposite right side 20. Referring to FIG. 2, a casting bay 30 is recessed into top side 14 of body 12. A base 32 forms the bottom of the casting bay 30.

(11) A first aperture 34 and second aperture 36 extend through base 32 and bottom side 16. Second aperture 36 intersects first aperture 34 in perpendicular orientation to form an aperture intersection 40. Aperture intersection 40 forms four opposing right angles 42 (see FIG. 2) on base 32 at the center of bay 30.

(12) In another embodiment, a first release hole 50 extends through base 32 and bottom side 16 between aperture intersection 40 and left side 18. In another embodiment, a second release hole 52 extends through base 32 and bottom side 16 between aperture intersection 40 and right side 20.

(13) In another embodiment, the distance between adjacent right angles 42 in base 32 is equal to the length of each side of the bezel of a jewelry article into which the finish machined irregular object (tooth 1) will be set (not shown).

(14) In another embodiment, the width of first and second apertures 34 and 36 are equal to the length of each side of the bezel of a jewelry article into which the finish machined irregular object will be set (not shown).

(15) In another embodiment, first and second apertures 34 and 36 are longitudinal in shape. In another embodiment, a left arm 54 extends from left side 18 of body 12, and a right arm 56 extends from right side 20 of body 12.

(16) In another embodiment, a method of manufacturing an irregularly shaped object with the above described center-cast tool 10 is disclosed. In this embodiment, a transparent adhesive tape 60 (not shown) is attached to bottom side 16 of body 12 so as to cover first and second apertures 34 and 36, and also first and second release holes 50 and 52 if provided. Display side 6 of tooth 1 is selected. Tooth 1 is positioned over aperture intersection 40 such that display side 6 is in contact or near contact with all four of the right angles 42 on base 32.

(17) Display side 6 is secured to adhesive tape 60 at aperture intersection 40. Bay 30 is filled with a solidifying casting material, such as a polymer resin or other suitable material. The casting material is allowed to solidify around the irregular object—baby tooth 1. The solidified casting 70 and baby tooth 1 are then removed from bay 30 for further processing, such as shaping.

(18) In another embodiment, adhesive tape 60 is removed and a tool, such as a punch, is inserted into first release hole 50 and second release hole 52 to press solidified casting 70 free from bay 30 of center-cast tool 10.

(19) In another embodiment, an elastic band 62 (rubber band—not shown) is extended between the left and right arms 54 and 56 in tension such that elastic band 62 presses tooth 1 against opposing right angles 42 of base 32, securing tooth 1 in place to prevent movement away from the selected position of tooth 1.

(20) In another embodiment, solid casting 70 has a display side 72 associated with the side of the casting that was in contact with base 32 of bay 30. Solid casting has an off display side 74 associated with the side opposite to display side 72. Display side 72 of solid casting 70 has extensions 76 formed where the casting material filled first and second apertures 34 and 36. Display side 72 is located in a fixture 100 (not shown) configured to receive display side 72 of solid casting 70, and off display side 74 is ground to the thickness desired for mounting in a bezel of a jewelry article.

(21) In another embodiment, off display side 74 is located in a fixture 200 (not shown) configured to receive off display side 74 of solid casting 70. Solid casting 70 and baby tooth 1 are saw cut along lines adjacent to extensions 76 on display side 72 of solid casting 70.

(22) As used in the examples of the functionality of the embodiments disclosed, the irregularly shaped object is baby tooth 1. It will be appreciated by a person of ordinary skill that the utility of the devices and methods of this disclosure are not limited to the centering, casting, and machining of baby teeth, but may also apply to gemstones.

(23) It will be understood by one of ordinary skill in the art that the disclosures related to the various figures and embodiments can be mixed and matched to obtain desired results.

(24) While this invention has been described in connection with a one embodiment, it is not intended to limit the scope of disclosed method to the particular form set forth, but, on the contrary, is intended to cover such alternatives, modifications and equivalents as may be included within the spirit and scope of disclosed method as defined by the appended claims.