Methods of designing molds for machining cost reduction

摘要

An orthopaedic knee cutting block prepared by a process comprising the steps of: creating a mold with a first core detail and a second core detail, each of the core details corresponding to a volume; filling the mold with a mixture of a binder and a metal; releasing a green part from the mold, the green part having a first void corresponding to the first core detail and a second void corresponding to the second core detail; removing the binder from the green part; heating the green part to create a sintered part; and machining the part by sawing a cutting slot such that the cutting slot overlaps with the first void and the second void. Alternatively, the orthopaedic knee cutting instrument may be made by a simple metal casting method.

主权项

1. A method of preparing an orthopaedic knee cutting block, the method comprising the steps of:
a. creating a mold with a first core detail and a second core detail, each of the core details corresponding to a volume; b. filling the mold with a mixture of a binder and a metal; c. releasing a green part from the mold, the green part having a first void corresponding to the first core detail and a second void corresponding to the second core detail; d. removing the binder from the green part; e. heating the green part to create a sintered part, the sintered part including a region between the first void and the second void, the region including a first section of material and a second section of material; and f. plunging a slitting saw into the sintered part to remove the first section of material from the region between the first void and the second void, thereby forming a cutting slot which overlaps with the first void and the second void; wherein the orthopaedic knee cutting block includes the second section of material in the region between the first void and the second void.