Patent ID: 6375880
Filing Date: 2002-04-23
Classification: B29C,B29L,B33Y

Abstract:
A method of making a complex three-dimensional molded part, comprising the steps of:a) generating a mold by (i) sequentially depositing in a predetermined deposition fashion a plurality of mold layers each comprising mold material, at least one of said mold layers comprising a mold segment formed of said mold material and a support segment formed of support material, wherein said mold material being removing resistant against a first removing means and being removable by a second removing means, wherein said support material being removable by said first removing means; (ii) shaping a mold surface within a previously deposited mold layer of said plurality of mold layers by shaping at least one of said support segment and said mold segment prior to deposition of a subsequent mold layer above said support segment and said mold segment, said shaping including three dimensional material removal in correspondence with a predetermined configuration of said mold surface, said predetermined configuration being independent of said predetermined deposition fashion, and wherein said predetermined deposition fashion and said shaping provide final layers selected from the group consisting of: A) planar layers; B) non planar layers; C) wedge shaped layers; D) layers having an uneven thickness; E) layers having an undulating thickness; F) layers having a curved shape; and G) layers having different thicknesses; (iii) removing said support material from said mold by removing said support material by use of said first removing means; b) casting part material into said mold to produce said part; and c) removing said mold material by use of a second removing means, said second removing means not removing said part material.