Rapidly Re-Configurable Mold Manufacturing of Free-Form Objects

This paper describes geometric algorithms for manufacturing freeform objects using a re-configurable mold system. The proposed process involves a mold block, with n faces, in which the mold cavity is formed. Each face of the mold block holds a uniform grid of pins, which are used to approximate the part surfaces. The geometric algorithms presented in this paper analyze the part and determine the face of mold block from which the part model is approximated best using the pins from that face. By moving these pins in and out of the mold block, the shape of the mold cavity can be configured dynamically to suit the changes in the part geometry. Since the proposed process approximates free-form objects with discrete pins, a surface-error calculation method is also developed to control the accuracy. Computer implementation and examples are also provided in this paper.