Patent ID: 8424585
Filing Date: 2013-04-23
Classification: B22C,B29C,B29L,B33Y

Abstract:
1. A method for creating a pattern of a model, said method comprising the steps of: providing a mold frame forming a mold enclosure to receive a mold core on an inside wall surface of and extending inwardly into said mold enclosure, said mold core comprising an index post having a smaller outer dimension than said mold core, said mold frame forming a gate aperture, a mold material aperture, and an index aperture capable of receiving said index post; permanently affixing a model to said mold core; mounting a gate to said model; placing said mold core and said model in said mold frame such that said gate extends into and substantially seals said gate aperture, said mold frame configured to receive a liquid mold material through said mold material aperture; inserting said liquid mold material into said enclosure of said mold frame through said mold material aperture, said mold material capable of solidifying or curing into a flexible mold; after said mold material solidifies or cures into said flexible mold having a mold shape, removing said flexible mold from said mold frame; removing said mold core and model and gate from said flexible mold, thereby creating a cavity in said flexible mold substantially in the shape of said mold core and model, said gate forming a gate channel in said flexible mold; providing an injection frame having a mold receiving space having substantially said mold shape of said flexible mold, said injection frame forming an injection aperture; inserting an injection core into said flexible mold cavity; placing said flexible mold in said mold receiving space such that said gate channel is aligned with said injection aperture; injecting liquid pattern material into said flexible mold through said injection aperture such that said pattern material flows into said flexible mold cavity through said gate channel and around said injection core, said pattern material capable of solidifying or curing into a pattern; and after said pattern material solidifies or cures into a pattern, removing said injection core and said pattern from said flexible mold.