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Abstract

Open-celled metal structures are produced which have walls and webs of uniform strength throughout. The structures may also have an irregular surface pattern. To make a strengthened positive pattern, the method comprises application of at least one layer of a strengthening agent such as poly(methyl methacrylate) or polyester resin to a plastic substrate used for ceramic mold formation. The strengthened positive pattern is embedded in a ceramic mass, and heated to incinerate and remove the plastic substrate, which results in voids in the ceramic mass. Molten metal is poured into the ceramic mass. After solidification, the ceramic mass is removed to form the open-celled metal structure.

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First Claim