Appeal No. 2000-0093
Application No. 08/874,812
aforementioned slice panels 4, for example, based on the outline data for
each slice section which is obtained by a computer, the shape of the
outline for each slice section is drawn on recording paper by a printing
device which is the output unit for the computer. Then, a paper pattern for
each slice section is produced from this recording paper, and using said
paper pattern, the slice panels are cut out in an outline of a specific shape
using a cutter. In addition to this method of processing, by means of an
NC processing apparatus or the like, with the outline data for each slice
section obtained by the computer, it is possible to directly cut out slice
panels into outlines of a specific shapes without using a paper pattern.
Then, as shown in Figure 2, when multiple slice panels 1, 1, ... that
have been processed into a shape with a specific outline as described
above are aligned with one another and polymerized by binding with a
binding agent, metallic mold pattern 2 with an outline that is horizontal
with respect to the outline A of metallic mold is formed (S4). Next, the
aforementioned metallic mold pattern 2 is erased with sandpaper or the
like, or small pieces of molded styrofoam are pasted on; thus the fairing
process is performed to produce metallic mold pattern 2 completely in an
outline with a specific shape (S5).
. . .
After that, a metallic mold is cast by means of full mold casting
using the aforementioned metallic mold pattern that has been processed
by fairing. (S6). As is publicly known, full mold casting involves
embedding a metallic mold pattern in casting sand, then injecting a molten
mixture into the casting sand, with the heat of the molten mixture burning
away the metallic mold pattern. Then by filling a molten mixture into the
cavity formed by the external form of the metallic mold pattern in the
casting sand, a metallic mold with a shape that corresponds to the
metallic mold pattern is obtained. This completes the manufacture of the
metallic mold [translation, pages 5 through 8].
Tamura '541 discloses a method for manufacturing a metallic mold which is
essentially similar to that disclosed by Tamura '340. Of particular interest is that
a processor produces 3-D data that describes the whole image of the
mold to be built based upon the 2-D graphic data of the mold, and, based
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