Gelcast Molding with Rapid Prototyped Fugitive Molds

A technique for the rapid manufacture ofceramic components has been developed using rapid prototyping to generate molds for the required components. The process entails the fabrication offugitive tooling using rapid prototyping techniques from which ceramic articles are formed using gelcasting. In the gelcasting process, the mold cavities are filled with a fluid suspension of ceramic powder which sets to a solid form through the polymerization of gelling additives and application of heat. The mold is carefully removed by dissolution or heat treatment leaving the intact gelcast part. The "green" gelcast part is subsequently dried and sintered to full density. Computer aided manufacturing of the tooling using solid freeform fabrication techniques allows for complex shapes to be manufactured with minimal tooling cost. The technique is idealfor the manufacture of ceramic parts in small batch conditions or for prototyping of functional parts in design cycles. Cost and time reduction of a magnitude can be achieved.Mechanical Engineerin