Patent ID: 8056603

Claim:
A method for producing a casting die for a seat pad, the method comprising: a die data making step for making die data through designing a requisite die comprising a lower die portion and an upper die portion in compliance with a configuration of a seat pad as an article to be produced; an automatic processing preparation step for preparing processing data as to how processing is to be performed by a processing robot as an automatic processing machine on the basis of the die data; a robot data conversion step for converting said processing data into robot operation data; a die model cutting step for producing a lower cast die model and an upper cast die model by cutting a die model material with said processing robot based on said robot operation data, said die model material comprising polystyrene foam, said polystyrene foam being meltable by a molten aluminum alloy and capable of undergoing evaporation vanishing; a lower die mold making step for making a lower die mold by packing casting sand in a box whose upper side is open, with the lower cast die model produced in the die model cutting step being placed at a central part of the box, the casting sand being provided with a gate and solidified with bond to thereby obtain the lower die mold; an upper die mold making step for making an upper die mold by packing casting sand in a box whose upper side is open, with said upper die model produced in the die model cutting step being placed at a central part of the box, said casting sand being provided with a gate and solidified with bond to thereby obtain the upper die mold; a lower die portion casting step for casting said lower die portion by a lost-form casting method, pouring said molten aluminum alloy as a molten die material into the lower die mold made in the lower die mold making step; an upper die portion casting step for casting said upper die portion by said lost-form casting method, pouring said molten aluminum alloy as a molten die material into said upper die mold made in said upper die mold making step; a finishing and assembling step for finishing and assembling the die cast in the lower die portion casting step and the upper die portion casting step.