Ford Global Technolgoies, LLC

Ford Motor Company Limited

Robert Walter Grenkowitz

Furqan Zafar Shaikh

Robert F Novak

Gregory Hugh Smith

Craig Edward Burch

Gerald Adam Grab

Martin Andrew Brogley

Michael Raymond Rigley

Method of rapidly producing a contoured part, comprising: designing a computer graphic model of the part, sectioning the graphic model into graphic members which are at least one of blocks or slabs, carving a solid member (14-150 mm in thickness) for each of the graphic members, the solid member being proportion to and enveloping such graphic members, the carving being carried out by accessing two or more sides (opposite sides) of such solid member to at least essentially duplicate the corresponding graphic member, and securing the carved solid members together to replicate the graphic model as a usable unitary part. The method can be modified to make castings by carving wax or foam solid members which are assembled to form an investment pattern, the was pattern being used in a shell mold casting steps and the foam pattern being used in evaporative casting steps.

Rapidly making a contoured part

The present invention provides an improved method for defining complex geometries to transpose geometric surfaces accurately into tooling. The method for entering accurate position data defining geometric surfaces eliminates the entry of erroneous position data at the sharp edges and boundaries of geometric shapes, such as the intersections between geometric tooling surfaces and planar parting surfaces. The method further provides for the creation and interrelation of accurate design, manufacturing, and control data bases which are used to enhance the speed and accuracy with which tooling having geometric surfaces may be designed and produced. The method of the present invention further has a reverse engineering capability which accommodates design improvements, facilitates correction of manufacturing errors in tooling, and permits monitoring and repair of tooling wear more quickly and easily than known methods.

Method of defining complex geometries to transpose flow boxes into

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Romeo, MI, United States of America

Robert Walter Grenkowitz