Method and system for constructing a structural foam part

摘要

A method for constructing a structural foam part. The method comprises three steps. Step one calls for utilizing a rapid prototyping process to create a polymer mold. Step two requires filling the polymer mold with a material. The last step calls for heating the polymer mold and the material to heat set the material and to remove the polymer mold thereby forming the structural foam part. More specifically, the rapid prototyping process may be stereolithography, and the structural foam part may have a varying density such that different mechanical properties exist in different sections of the structural foam part.