Patent ID: 6857461

Claim:
A method of producing a reticular structure, said method comprising the steps of: a) placing a reticulated foam pre-structure into a first container having a lid; b) infiltrating said foam pre-structure with a refractory mold material; c) solidifying said refractory material to form a refractory mold; d) withdrawing said refractory mold along with said foam pre-structure from said first container; e) removing said foam pre-structure from said refractory mold; f) placing said refractory mold into a second container having at least one opening for pouring in a molten substance and at least one wall, wherein said second container is greater in size than said refractory mold so as to leave a gap between said refractory mold and said at least one wall; g) infiltrating said refractory mold with said molten substance to form a reticular structure; h) pouring a jacket material over said refractory mold so as to fill said gap with said jacket material to form a plate; i) cooling said reticular structure by maintaining a temperature of said second container, and particularly of said at least one wall, that is lower than a temperature of said molten substance so as to draw heat from said reticular structure into said second container, and particularly through said plate; and j) after said molten substance has solidified, withdrawing said reticular structure from said second container and removing said refractory mold from said reticular structure.