Generating sacrificial multi-piece molds using accessibility driven spatial partitioning

This paper describes an algorithm based on accessibility-driven partitioning approach to automate the design of sacrificial multi-piece molds. Sacrificial multi-piece molds are used for producing geometrically complex gelcast ceramic parts. The algorithm presented in this paper analyzes the accessibility of the gross mold shape and partitions it using accessibility information. Each partitioning step improves accessibility of decomposed mold pieces. By performing successive decomposition, this algorithm finally produces a set of mold components that are accessible and therefore can be manufactured using milling and drilling operations. Using the algorithm presented in this paper, mold design steps can be significantly automated for making geometrically complex parts and facilitating the creation of physical part from the CAD model in a matter of hours.