Holder block system and methods for metal casting

Abstract

A holder block system suitable for producing metal castings. The holder block system includes a holder block primary mold that has one or more cavities that accept a sub-mold that incorporates the features of the part to be cast, wherein the sub-mold can be produced utilizing 3-D printing. Methods of preparing holder block patterns and cast objects are with the holder block system disclosed.

What is claimed is: 
     
         1 . A holder block system, comprising:
 a primary mold comprising a cavity; and   a 3-D printed sub-mold located in the cavity, the sub-mold having an outer surface adapted to mate with at least a portion of the cavity, and wherein an interior surface of the sub-mold includes at least one negative image of a component to be cast.   
     
     
         2 . The holder block system according to  claim 1 , wherein the sub-mold is formed as a single piece. 
     
     
         3 . The holder block system according to  claim 1 , wherein the primary mold comprises a gating system, wherein the sub-mold includes an ingate adapted to align with the gating system on the primary mold and thereby accept a molten metal into an interior cavity of the sub-mold. 
     
     
         4 . The holder block system according to  claim 3 , wherein the sub-mold is free of a separate core and a cope and drag. 
     
     
         5 . The holder block system according to  claim 1 , wherein the primary mold does not contain any features of a part to be cast utilizing the holder block system. 
     
     
         6 . The holder block system according to  claim 1 , wherein the sub-mold is formed from a different material than the primary mold. 
     
     
         7 . The holder block system according to  claim 1 , wherein the primary mold comprises a flask and a molding composition located within the flask, with a cavity being present in the molding composition. 
     
     
         8 . The holder block system according to  claim 3 , wherein the primary mold gating system comprises one or more of a sprue, well, and runner. 
     
     
         9 . A method for producing a holder block system, comprising the steps of:
 providing a primary mold having at least one cavity and one or more of a sprue, well, runner and ingate;   providing a 3-D printed sub-mold including an interior surface having a shape of an object to be molded;   inserting the sub-mold into the at least one cavity of the primary mold to form the holder block system.   
     
     
         10 . The method according to  claim 9 , further including the step of forming the primary mold by adding a molding composition to a flask and incorporating a pattern into the molding composition in the form of the at least one cavity. 
     
     
         11 . The method according to  claim 10 , further including the step of forming a gating system in the molding composition that includes one or more of a sprue, well, runner, and end gate. 
     
     
         12 . The method according to  claim 11 , further including the step of forming an ingate on the sub-mold and aligning the ingate with the gating system of the primary mold. 
     
     
         13 . The method according to  claim 12 , wherein the primary mold is formed so that it does not contain any features of a part to be cast with the holder block pattern. 
     
     
         14 . A method for producing a metal casting, comprising the steps of:
 obtaining a primary mold having at least one cavity;   obtaining a sub-mold including an interior surface having a shape of an object to be cast, wherein the sub-mold is 3-D printed and has an external shape adapted to be placed in at least a portion of the cavity of the primary mold;   inserting the sub-mold into the at least one cavity of the primary mold; and   adding a molten metal to a portion of the primary mold such that the molten metal flows from the primary mold into a cavity of the sub-mold including the interior surface.   
     
     
         15 . The holder block system according to  claim 14 , wherein the sub-mold is free of a separate core and a cope and drag. 
     
     
         16 . The holder block system according to  claim 15 , wherein the primary mold comprises a gating system, wherein the sub-mold includes an ingate aligned with the gating system on the primary mold and thereby accept the molten metal into an interior cavity of the sub-mold. 
     
     
         17 . The holder block system according to  claim 16 , wherein the primary mold does not contain any features of a part to be cast utilizing the holder block system. 
     
     
         18 . The holder block system according to  claim 17 , wherein the sub-mold is formed as a single piece; and
 wherein the primary mold gating system comprises one or more of a sprue, well, and runner.