Creation of an active 3d-mold (discussion of theoretical possibilities)
I want to discuss with you the possibility of creating an active 3D-casting mold.
I apologize in advance if these devices already exist, but I have not heard of them.
The idea is to create a programmable 3D mold, that is, something similar to a 3D printer, only for casting. That will allow the use of a wide range of consumables.
(Image is conditional, only for understanding the general idea) The
foundry part of the device will represent a box in the walls of which there will be spokes in rows that can be immersed in this box at different depths (from wall to wall). The end of the spokes inside the box is a linear wall.
1. The first step is to create a mold. that is, the reverse formation of the model, say in Autodesk inventor
2. Further, the cutting of the model form into layers, the lower the layer profile, the better the cast product will come out. (I used 123D Make for example)
(Below is the primary form for the template, a primitive mushroom. I'm not an artist)
3. Breakdown of each layer into depths for the entry of spokes, (forming the model wall). The dotted line indicates the problem area for this type of form construction.
The internal appearance of the wall should look something like this, only the width of such a spoke should be no more than a couple of millimeters.
4. Further, it is possible to place a mold for air pressing inside (an inflated ball fills the entire volume of the template), which will slightly reduce irregularities from separation into layers. Or adding liquid material inside the mold, which during the rotation of the mold will solidify evenly on the walls of the mold. (Wax, Plastic)
5. The exit of the spokes to the initial position, the notch of the finished model.
Pros and cons:
The main disadvantage is the inability to build 2-3 complex internal forms on one layer due to the intersection of the trajectories of the spokes. The square of the cast surface.
The pluses include a wide range of casting materials (Wax, Cement, Plastic, Glass, Metal). The shape changes and does not require the constant creation of patterns for casting from other materials.
It should turn out to be a good analogue of 3D printing, for objects with low resolution and simple shape. (Example: landscape models, vases, Christmas toys, etc.)
PS The problem of the internal shape in the form can be solved by creating interlocking cells on all axes of the cell. (As an option)