Patent ID: 10421119

Abstract:
A method of forming a component including coupling an array of receptacles to a mold core. Each receptacle in the array contains an amount of uncured mold material. The method further includes forming a layer of fugitive material on the mold core such that the array of receptacles is encapsulated within the layer of fugitive material. The method also includes forming a layer of uncured mold material on the layer of fugitive material, thereby forming an uncured mold assembly. The uncured mold assembly is heated to a temperature that solidifies the uncured mold material within each receptacle and of the layer, thereby forming an array of pins and a layer of solidified mold material. The uncured mold assembly is also heated to the temperature that removes the layer of fugitive material from between the mold core and the layer of solidified mold material such that a mold cavity, including the array of pins, is defined therebetween.