Patent ID: 7270167
Filing Date: 2007-09-18
Classification: B22D

Abstract:
1. A method of making a metal and non-metallic fiber composite mold comprising the steps of: (a) providing a matrix having a shape to be molded; (b) providing an underlying metal layer on said matrix; (c) placing a sheet over the underlying metal layer, the sheet including a plurality of filaments, said filaments being spaced apart from one another and defining gaps therebetween; and then (d) spray depositing an additional metal layer by making a plurality of passes with at least one spray gun so that the metal of said additional metal layer merges with the metal of said underlying metal layer in said gaps; (e) allowing the sheet to remain between the underlying metal layer and the additional metal layer and; (f) restraining said sheet in position on said underlying layer during at least a part of said step of depositing said additional metal layer, wherein said restraining step includes providing a mesh over said sheet.