Patent ID: 7402265

Claim:
A method of making and using a reformable tool having a surface portion characterized by a desired shape, the method comprising: providing a volume of a mixture in a formable state, the mixture having solid and liquid-containing carrier components wherein the solid component comprises a plurality of solid bodies, and the carrier component fills the interstices between the bodies, and includes an excess amount of carrier beyond an amount that would be needed to fill the interstices when the bodies are packed, the excess amount of carrier thus allowing the mixture to be in the formable state; causing a surface of the volume to assume the desired shape; extracting the excess amount of carrier to cause the mixture to transition from the formable state to a stable, force-resisting state where the bodies make nested, packed, interlocking or otherwise stable consolidated contact so that a portion of the volume has a stable surface portion characterized by the desired shape; subsequently conforming a body of formable material to the stable surface portion of the volume in order to impart a shape to the body of formable material that is complementary to the desired shape; subsequently stabilizing the body of formable material so that the body retains the shape that is complementary to the desired shape; and subsequently reintroducing a sufficient volume of carrier to allow the mixture to transition from the stable, force-resisting state to the formable state.