GB2572766A - A moulding system, apparatus and method - Google Patents

Abstract

A casting cell 10 for pressure casting comprising a support frame 12 and an upper 14 and lower panel 16, spaced apart to receive an object between, and moveable relative to one another to apply pressure to the object. The cell may be used for slip casting. The moveable panel may be moved by a pneumatic or hydraulic means. The cell may have a further panel 18 with inflatable tubing 20 arranged between the further panel and the upper panel. The tubing may be layflat tubing and the further panel may be fixed relative the frame. The upper and lower panels may be tilted with respect to the horizontal whilst remaining parallel to one another. The upper or lower panel may have a port 22 for providing service to on object, or may have a locating element 24 for positioning of the object between the panels.Also claimed are a mould with two separable portions with a protrusion for engagement for a corresponding tool; a tool comprising a sleeve portion with internal dimensions at least the same as a corresponding protrusion; a rack for storing casting cells with shelves comprising locating elements and a method of manufacturing moulded items.

Description

A moulding system, apparatus and method

Field of the invention

The present invention relates to a moulding system, apparatus and method. The present inventive concept is especially relevant to casting and moulding of ceramic materials but certain aspects of the inventive concept may also be applicable to other materials such as composites and other moulding compounds such as rubber, cement, plaster or more generally to any material where the process time is longer than the demoulding process.

Background to the invention

Casting and moulding are well-known processes, used in the manufacture of items of ceramics and other materials. In a known process, a liquid - sometimes referred to as a slurry or slip - may be introduced into a mould. The liquid is subsequently transformed into a solid and the solidified material removed from the mould.

- 2 In pressure casting a slip (also referred to as a slurry) is provided, the slip comprising a carrier fluid such as water and a ceramic material dispersed within the carrier. In use, the slip is introduced into a mould and then pressure is applied to the mould to drive out the carrier fluid.

Of especial interest to the present inventive concept is a slip casting process whereby a slurry or slip including a ceramic material (for example) is poured into a mould. The carrier fluid such as water of the slip is drawn or forced out (e.g. under gravity, under a vacuum or by some physically, hydraulically or pneumatically applied pressure) leaving an inside layer of solid ceramic. Once the solid layer is thick enough, the excess slip can be removed from the mould if desired. As a consequence of a moisture drop such as by applied pressure, the material develops sufficient rigidity to allow it to be removed from the mould, the cast item can be removed from the mould, usually by separating separable parts of which moulds are commonly constituted.

The present inventive concept can, however, be applied to other materials to be cast or moulded. For example, moulding of composite materials can be achieved using substantially the same apparatus and method steps as disclosed herein.

Our earlier applications such as WO2014/118499, WO2015/049486 and WO2017/068323 describe aspects of pressure casting.

Previous systems in the field have generally been arranged to produce moulded products in relatively large batches of identical products which are subsequently stored for onward distribution. However, the need has arisen for a more demand-driven approach in which products are not stored but rather are made substantially to order. This necessitates a more adaptable manufacturing process, which shortens lead times and supply chains.

Summary of invention

The present inventive concept involves several aspects which may each operate discretely or interact with one another depending how the aspects are deployed.

- 3 A first aspect of the present inventive concept is directed to a casting cell for use in pressure casting, the cell comprising a support frame, an upper panel and a lower panel spaced apart so as to receive an object between the upper and lower panels, the upper and lower panels being moveable relative to one another for application of pressure to such an object.

One of the upper or lower panel may be fixed relative to the support frame. The other of the upper or lower panel may be moveable relative to the support frame. Movement of one panel relative to the support frame enables that panel to apply pressure to an object between the upper and lower panels.

A moveable panel may be moved by a pneumatic or hydraulic means.

The pneumatic or hydraulic means may comprise a further panel having tubing arranged between the further panel and the upper panel, the tubing being inflatable by a fluid. Thus, inflation of the tubing by a fluid exerts a force on the upper panel to in turn apply pressure to an object between the upper and lower panels. The tubing may be layflat tubing. The tube may be inflated by pressurised air, water or other suitable fluid. Such a fluid may be supplied by a service line.

The further panel may be fixed relative to the support frame.

The upper and lower panel may be maintained substantially parallel to one another.

In a starting orientation, the upper and lower panels are substantially horizontal. The upper and lower panels may be adapted to be tilted with respect to the horizontal while remaining substantially parallel to one another. Tilting may improve drainage from an object received between the upper and lower panels. Especially, the object received may be a mould. Thus, tilting may improve the extent and/or speed of drying of a ceramic cast.

Such tilting may be effected by moving the support frame on a pivoting means. Thus, components of the casting cell move in concert with one another, maintaining their positional relationship with one another and the support frame while tilting takes place.

The upper or lower panel may be provided with at least one port for providing a service to an object received. Such an object may be provided with a service by a corresponding

- 4port. A service may be a fluid supply such as an air supply (or vacuum) or water supply or the like. A port may also be adapted to supply electricity or thermal energy.

Preferably, the lower panel is provided with at least one port.

The upper and/or lower panel may be provided with at least one locating element for assisting the positioning of an object into a preferred position between the upper and lower panels. Thus, an object may be positioned so that corresponding ports on a panel and on an object are aligned so that a service may be provided.

The at least one port is connected to a service line such as a pipe or the like. A service line may be of metal or plastics or a flexible hose material, for example. A service line may further comprise a pressure vessel. A service line may further comprise a control valve. The control valve may be connected to and operated by an electronic controller.

Such a service line may be connected in turn to a distribution line.

The casting cell may further comprise a moveable side panel. Such a side panel is arranged so as to be moveable to engage with an object. Thus, pressure might be applied to an object in two substantially perpendicular dimensions. Such a side panel may be moved by pneumatic or hydraulic means including by way of inflation of a tube as described above. The casting cell may comprise two side panels. Both side panels may be moveable.

The first aspect of the present inventive concept may further provide a plurality of casting cells arranged in a matrix. The matrix may comprise casting cells arranged in rows or columns or in both rows and columns.

In a preferred arrangement, there is provided a matrix comprising at least three casting cells arranged in a column - i.e. with casting cells arranged substantially vertically with casting cells stacked above one another.

A matrix of casting cells allows for a service line of each of the casting cells to be supplied by a common distribution line for each service. Thus, for example, there need only be a single compressed air distribution line, a single water distribution line, etc. which can provide services to all of the casting cells of a matrix.

- 5 Furthermore, a matrix of casting cells arranged in proximity to one another and in predetermined (i.e. known) locations assists in efficient operation of a casting method especially as set out in one or more aspects of the present inventive concept.

In a preferred arrangement, two columns are provided substantially adjacent to one another, which share a common distribution line for each service.

Further columns may be provided, sharing common distribution lines as described.

A second aspect of the present inventive concept is directed to a mould comprising two separable mould portions which correspond with one another to form a complete mould when brought together, each mould portion comprising a substantially surface wall and a perimeter wall, the perimeter wall comprising a protrusion extending outwardly therefrom, the protrusion being adapted for engagement with a corresponding tool.

The surface wall and the perimeter wall are arranged so that when the mould portions are brought together the mould portions form an internal moulding volume. In a preferred arrangement, the surface wall is substantially planar and the perimeter wall is arranged substantially perpendicularly to the surface wall.

At least one mould portion may comprise a port formed within the perimeter wall, through which fluid may pass between an inner part of the mould and the outside of the mould.

The port may be formed separately from the protrusion, or may be formed integrally with the protrusion. In other words, the port may be formed as a hollow portion of the protrusion or the port may be distinct from the protrusion.

The protrusion may be formed by an element having a substantially circular crosssection such as a tubular element or a bolt, an axis of the protrusion being substantially perpendicular to the perimeter wall from which the protrusion extends. The protrusion may thus provide a region suitable for gripping by the aforementioned corresponding tool.

The protrusion may be formed with an external profile having regions of differing external diameter. For example, the protrusion may have a first region of a first external diameter adjacent a second region of a second external diameter. Preferably the second

- 6 external diameter is less than the first external diameter. The protrusion may have a third region of a third external diameter adjacent the second region, not adjacent the first region. Preferably, the second external diameter of less than the first external diameter and the third external diameter. The first and third external diameters may be substantially the same. Thus, the second region may form in effect an annular channel between the first and third regions. In this preferred arrangement, such an annular channel can provide a gripping region for a suitable corresponding tool. The annular channel provides a limitation of positioning and axial movement of such a tool.

A mould portion may comprise two protrusions. Providing two protrusions assists stability when the mould is being engaged by a corresponding tool.

A mould portion may be provided with a port. The port may be located approximately between two protrusions.

The or each protrusion on a mould portion may be arranged to be located in close proximity to a corresponding protrusion on another mould portion, so that when the mould portions are in use as a complete mould the protrusions are similarly located to each other.

The protrusion may be relatively small compared with the overall size of the mould.

The mould portions may comprise poly(methyl methacrylate) (PMMA). The mould portions may comprise a plurality of pores formed within the mould portions. The pores may be large enough to permit ingress of slip, water and air.

At least one mould portion may comprise an identifier. Such an identifier may be a radio frequency identifier (RFID) or barcode or the like.

A suitable tool must be able to be removably attached to the protrusion with high accuracy, precision, repeatability and rigidity so that unwanted motion of the mould is avoided. It is important that opening a mould to remove a moulded product is managed carefully to avoid damage to the moulded product as the moulded product is likely to be fragile. Furthermore, a suitable tool preferably provides means for provision of electrical power, electronic signals, process fluids and the like to the mould.

- 7A tool may comprise a sleeve portion which is adapted to have internal dimensions of at least the same as the largest dimensions of the regions of a corresponding protrusion. Thus, the sleeve portion of the tool may be positioned so that the protrusion is substantially within the sleeve portion.

The tool may further comprise a clamping means within the sleeve portion, adapted to clamp the protrusion. The clamping means may comprise a portion which is adapted to form a region of reduced internal diameter, to engage with a region of the protrusion.

The clamping means may comprise two clamping portions which are moveable towards and away from each other substantially perpendicularly to an axis of the sleeve portion. The two clamping portions may thus form a gripping engagement with the protrusion when the protrusion is within the sleeve portion.

The or each clamping portion may comprise a bolt.

The sleeve portion may be substantially tubular.

In a preferred arrangement in which the tool comprises two clamping bolts, use of such a tool with a protrusion having an annular channel may provide for a strong gripping engagement with a protrusion by limiting movement of the protrusion both axially of the tool and non-axially.

As mentioned, the protrusion may be relatively small compared with the overall size of the mould. Thus, the protrusion and a corresponding tool may provide a compact means for moving and lifting a mould. The skilled reader will appreciate that a mould and any contents of the mould may be fairly large and heavy.

The tool may comprise a sleeve portion and clamping means corresponding to each protrusion. Thus, if each mould portion has a single protrusion - for example - the tool may comprise two tubular sleeve portions each with clamping means.

The sleeve portions may be moveable relative to one another in at least one dimension. Thus, movement of the sleeve portions may be used to bring together or move apart mould portions.

- 8 The tool may be rotatable, so that sleeve portions may move collectively around a common point or axis while maintaining their positional relationship to one another.

One envisaged tool comprises four sleeve portions arranged in substantially a rectangle, each sleeve portion having a clamping means arranged within it, the clamping means comprising two bolts moveable along a common axis towards and away from each other, the common axis being substantially perpendicular to an axis of the respective sleeve portion.

As mentioned, the sleeve portions may be moveable relative to one another in at least one dimension. The sleeve portions may be moveable relative to one another in two dimensions. The tool may be rotatable, so that sleeve portions may move collectively around a common point or axis while maintaining their positional relationship to one another.

Such a tool may be arranged on a robot arm. The robot arm may be moveable in three dimensions. The robot arm may be controllable by a computer as described herein.

The tool or part of the robot arm may be provided with a suitable means for reading an identifier of a mould portion, such as an RFID reader or barcode reader or the like.

It is intended that the present inventive concept includes the arrangement of the protrusion and the arrangement of the tool independently, as well as in combination with one another.

A third aspect of the present inventive concept is directed to a rack for storing casting cells comprising a column comprising two or more shelves arranged substantially vertically with respect to one another, each shelf comprising at least one locating element for assisting the positioning of an object into a preferred position with respect to the shelf.

Preferably, each shelf has at least two locating elements.

The rack is preferably attached to a fixed object in a known position, such as a known location of a floor.

- 9 The shelves have a known positional relationship with the rack, and thus the floor when the rack is attached to a floor in a known location. The or each locating element of each shelf also has a known positional relationship with the shelf. Thus, an object of known size and shape which is positioned on a shelf using the locating element thereof will have a position known in three dimensions relative to a pre-determined point on the floor.

This is important because in an aspect of the present inventive concept it is important that locations of objects are known very precisely so that they can be moved from one known location to another known location for processing, storage and the like.

A fourth aspect of the present inventive concept is directed to a method of manufacturing moulded items comprising the steps of:

- directing a tool to engage with a protrusion of a pre-selected mould;

- directing the tool to move the mould to a pre-determined casting position within a casting cell;

- once the mould is in the casting position, activating one or more components of the casting cell in a casting cycle;

- when the casting cycle is complete, directing the tool to engage with the protrusion of the mould;

- directing the tool to move the mould to a pre-determined conveyor position with respect to a conveyor;

- directing the tool to separate the mould portions; and

- subsequently directing the tool to bring the mould portions together.

The method may be repeated one or more times.

The method may be effected in respect of more than one mould. Steps of the method may be effected in an interleaved way. For example, one or more of the steps of the method may be effected in respect of a first mould, then one or more steps of the method may be effected in respect of another mould, before further steps are effected

- 10 in respect of the first mould, and so on. Thus, moulds can be at different stages at different times. This is important because it enables a relatively continuous production of moulded products.

The mould may be arranged according to an aspect of the present inventive concept.

The tool may be arranged according to an aspect of the present inventive concept.

Each step of directing the tool may include provision of location information to a controller of the tool. Preferably, the tool is operated remotely by computer control. Thus, for example, the tool may be moved and operated by a robot arm” type apparatus controlled remotely by computer.

It is important for each step of directing the tool that precise and accurate location information is available so that the tool can be positioned correctly with respect to the mould and with respect to a desired position. For example, when the tool is directed to engage with a protrusion of a mould, it is important that the tool is positioned correctly so that the engagement with the protrusion is firm and secure so that the tool can then move the mould to another position. The mould may be large and heavy even when there is no casting material within it; the protrusion is relatively small compared with the overall size of the mould - meaning that it is important for the tool to be positioned properly for engagement.

It is also important that each step of the method is effected in a timely manner. This not only improves the overall efficiency of the moulding process, but certain steps are ideally carried out promptly after a previous step so as to improve the quality of a moulded product. For example, once a casting cycle is complete it is important that the moulded product is removed from the mould quickly so as to avoid fluid which may be present in the mould from re-entering the moulded product.

Precise positioning may be aided by information regarding the location of individual parts of an apparatus. This may be aided by the provision of locating elements. For example, a shelf may be provided with locating elements so that a mould can be placed in a pre-determined position with respect to the shelf. Then, when the mould is to be moved again, its position is already known precisely.

- 11 The tool may engage a protrusion by positioning a sleeve portion over a mould protrusion and engaging a clamping means of the tool with the protrusion.

The casting position may be within a casting cell. In practice moving the mould into the casting position may include inserting the mould between an upper and lower panel of a casting cell.

The method may further comprise a step of identifying a location of the mould within a storage area. The storage area may be a rack, which may be arranged according to an aspect of the present inventive concept. Such a step may be effected as the first step of the method.

The method may further comprise a step of directing the tool to move the mould to a position within a storage area. Again, storage area may be a rack, which may be arranged according to an aspect of the present inventive concept. Such a step may be effected as the final step of the method.

The casting cycle may further comprise steps of:

- providing a slip material to the mould by way of a port of the mould; and

- applying pressure to the mould for a pre-determined period to remove fluid from the mould.

The casting cycle may further comprise the step of providing air to the mould to further displace fluid from the mould.

The casting cycle for different moulds may be different. For example, a larger mould may require pressure to be applied for a longer period than may be required for a smaller mould. The casting cycle for different materials may be different. For example, certain materials may require more or less pressure to be applied for a longer or shorter period.

The casting cycle may further comprise the step of tilting the mould. Such tilting may take place before, during and/or after pressure is applied.

A controlling computer may be provided with the information required to put the method into effect for different moulds and materials etc.. One or more steps of the method may be put into effect by a program for a controlling computer. Such a program

- 12 may take into account differing requirements for casting cycles, and manage the method according to needs (such as demand for particular moulded products) and requirements of moulds and materials.

The present inventive concept allows for different moulds to be processed substantially simultaneously.

Once the tool has separated the mould portions, the method may further comprise the step of introducing air to at least one mould portion via a port. Such a step may aid the removal from a moulded product from the mould portion, by applying pressure to the moulded product in a direction away from the mould portion.

After the moulded product has been removed, the mould portions may be brought back together.

Once the tool has brought the mould portions together, the method may further comprise a step of applying a washing cycle to the mould. Such a washing step may comprise applying water to the mould. A washing cycle may further comprise a drying step.

Then a mould is ready to be used again.

Ideally, the various parts needed to implement the method are arranged in relatively close proximity to one another. Thus, as mentioned above, the tool may be operated by a robot arm” type apparatus. This arrangement is advantageous because the various parts can be kept physically separately in a facility away from human operatives. Thus, potentially large and heavy items such as moulds can be moved around quickly and efficiently but overall safely. As an example, a functioning system of the present inventive concept may be provided within a floor area of approximately 4m x 4m, i.e. approximately 16m².

The present inventive concept thus provides aspects of a system, apparatus and method which enables moulded products to be provided relatively quickly in response to demand, in contrast with previous arrangements which have tended to provide large numbers of identical products in batches for storage and subsequent distribution. The present inventive concept thus provides for a more efficient and less resource-intensive

- 13 approach which requires less space and due to reductions in unnecessary manufacture reduces demands of raw materials and energy. Furthermore, by enabling supply chains to be shorter the present inventive concept reduces transport costs by enabling production of moulded products in locations physically closer to an end consumer.

Detailed description of the invention

Examples of aspects embodying the present inventive concept will now be described with reference to the accompany drawings, in which:

Figures 1 and 2 show views of a casting cell;

Figures 3 to 10 show views of matrices of casting cells;

Figures 11 to 13 show views of a tool;

Figures 14 and 15 show a conveyor;

Figures 16 to 18 show a rack; and

Figure 19 shows a system embodying several aspects in combination.

The drawings will be described in detail, but it will be clear to the skilled reader that due to different views of similar features, certain elements will be described which are not visible in certain drawings.

Turning to Figures 1 and 2, a casting cell 10 which has a support frame 12 within which an upper panel 14 and a lower panel 16 are arranged. In this example, the lower panel 16 is fixed relative to the support frame 12; the upper panel 14 is moveable relative to the support frame 12. A further panel 18 is fixed relative to the support frame 12 and is connected to the upper panel 14 by way of portions of inflatable tubing 20. In use, the portions of inflatable tubing 20 may be inflated to exert a downward force on the upper panel 14. Thus, the upper panel 14 may be moved downward to in turn exert a force on an object which may be arranged between the upper panel 14 and the lower panel 16.

- 14The lower panel 16 has ports 22 formed within it; the ports 22 allow services to be provided to an object which may be arranged between the upper panel 14 and the lower panel 16. Services may be a supply of liquid such as slip or water, or air. Services may be provided to the ports 22 by way of a supply line 26.

The lower panel 16 also has spacers 24 which act as locating elements to aid predictable and precise positioning of an object.

The further panel 18 is provided with supply lines 28 for providing for example compressed air to the inflatable tubing 20.

Turning to Figures 3 to 15, matrices of casting cells 10 are shown in differing configurations and views, so that certain features mentioned are shown in some figures and not in others. The skilled reader will appreciate that not every feature described is essential to every configuration embodying the present inventive concept. Furthermore, to aid clarity not every feature present in each figure is labelled individually. For example the skilled reader will appreciate that a casting cell 10 will have various features which are not necessarily labelled and described in each figure.

Figure 3 shows a front elevation of a matrix 30 of casting cells 10 in which two columns of three casting cells are arranged so that there are three rows of two casting cells 10 within a framework 32. Moulds 100 are shown within each casting cell 10. Each casting cell 10 has a pressure vessel 34 connected thereto.

Figure 4 shows substantially the same matrix 30 as in Figure 3, from a side elevation. In this figure, supply lines 26, 28 are shown more clearly.

Figure 5 shows substantially the same matrix as in Figures 3 and 4 from a rear elevation. As can be seen in this figure, a common supply line 36 is used for several casting cells

10.

Figure 6 shows a slightly different arrangement of a matrix 30 of casting cells 10 in a front perspective view. Figure 7 shows the same arrangement of a matrix 30 as in Figure 6, from a rear perspective view.

- 15 Figure 8 to 10 show a similar arrangement to that of Figures 3 to 5, but further including a mesh 38 at the rear of each casting cell 10. A mesh 38 can act as a locating element as well as protecting components at the rear of the cells 10 and matrix 30.

Turning to Figure 11, a tool 40 is shown from a front elevation. The tool 40 comprises 4 tubular sleeve portions 42 attached to a respective support arm 44, 46. The upper two sleeve portions 42 are attached to a first support arm 44 and the lower two sleeve portions 42 are attached to a second support arm 46. Thus, the upper two sleeve portions 42 can move relative to the lower two sleeve portions 42 by relative movement of the respective support arms 44, 46.

Within each sleeve portion 42 are two clamping bolts 48 which are moveable towards and away from one another perpendicularly to an axis of the sleeve portion 42 to form a clamping means.

The support arms 44, 46 may be connected to and controlled by a robot arm (not shown). Thus, the sleeve portions 42 may be moved in three dimensions.

Thus, in use, movement of the support arms 44, 46 can position the sleeve portions 42 over corresponding protrusions of a mould (for example). Then, the clamping bolts 48 can be engaged to secure the tool to protrusions.

Figure 12 and 13 show the same tool as in Figure 11, from a side view and perspective view respectively.

Figures 14 and 15 show a conveyor 50 in plan view (Figure 14) and in a side elevation (Figure 15).

Figure 16 shows a front elevation of a rack 52 having side members 54 and shelves 56. Each shelf 54 is adapted to accommodate a mould 100. Figure 17 shows the same rack 52 in side elevation. Figure 18shows the same rack 52 in a front perspective view.

Figure 19 shows a plan view of a layout of a system 60 incorporating many of the features of the aspects described in the present inventive concept. A casting matrix 30 is located on one side of and forms part of a perimeter of a fenced off area 62. Fenced off area 62 is not accessible by human operatives. A robot arm 64 is arranged approximately in the centre of the fenced off area 62 and is moveable within that area.

- 16 The robot arm 64 is equipped with a tool 40 as described. The system 60 further comprises a rack 52 and a conveyor 50. Part of the conveyor 50 is within the fenced off area 62 and part of it is outside. The rack 52 is accessible from one side by a human operative. Thus, a mould 100 can be placed into the rack 52 by a human operative during operation of the system 60.

In use, a mould 100 which may initially be in the rack 52 can be engaged by the tool 40 by operating the robot arm 64 to an appropriate position with respect to the mould 100 and engaging the clamping bolts of the tool 40. Subsequent movement of the robot arm 64 thus moves the mould 100. The mould 100 can then be placed into a casting cell within the casting matrix 30. The tool 40 may then be disengaged by releasing the clamping bolts.

A casting cycle can then be performed on that mould 100 - including, for example, filling the mould 100 with slip, applying pressure to the mould 100 with a casting cell, tilting the mould 100.

Once the casting cycle is complete, the robot arm 64 can be moved into an appropriate position with respect to the mould 100 and the clamping bolts of the tool 40 can be engaged. Subsequent movement of the robot arm 64 thus moves the mould 100. The robot arm 64 can then move the mould 100 to a position appropriate to a portion of the conveyor 50 within the fenced off area 62. The tool 40 can move the sleeve portions 42 with respect to one another to separate portions of the mould 100. If needed, the tool 40 can be supplied with air to separate a moulded product from the mould 100. Thus, the moulded product can be released from the mould 100 and moved to another part of a wider facility by the conveyor 50.

The robot arm 64 and tool 40 can then move the mould portions together and the mould can be used again as needed.

Claims (29)

1. A casting cell for use in pressure casting, the cell comprising a support frame, an upper panel and a lower panel spaced apart so as to receive an object between the upper and lower panels, the upper and lower panels being moveable relative to one another for application of pressure to such an object.

2. A casting cell according to claim 1 wherein a moveable panel may be moved by a pneumatic or hydraulic means.

3. A casting cell according to claim 1 or claim 2 wherein the pneumatic or hydraulic means comprises a further panel having tubing arranged between the further panel and the upper panel, the tubing being inflatable by a fluid.

4. A casting cell according to claim 3 wherein the tubing is layflat tubing.

5. A casting cell according to claim 3 or claim 4 wherein the further panel is fixed relative to the support frame.

6. A casting cell according to any preceding claim wherein the upper and lower panels are adapted to be tilted with respect to the horizontal while remaining substantially parallel to one another.

7. A casting cell according to any preceding claim wherein the upper or lower panel is provided with at least one port for providing a service to an object received.

8. A casting cell according to any preceding claim wherein the upper or lower panel is provided with at least one locating element for assisting the positioning of an object into a preferred position between the upper and lower panels.

9. A casting cell according to any preceding claim wherein the casting cell further comprises a moveable side panel.

10. A matrix of casting cells comprising a plurality of casting cells in accordance with any preceding claim.

11. A matrix of casting cells according to claim 10, three casting cells are arranged in a column.

12. A mould comprising two separable mould portions which correspond with one another to form a complete mould when brought together, each mould portion comprising a substantially surface wall and a perimeter wall, the perimeter wall comprising a protrusion extending outwardly therefrom, the protrusion being adapted for engagement with a corresponding tool.

13. A mould according to claim 12 wherein at least one mould portion comprises a port formed within the perimeter wall, through which fluid may pass between an inner part of the mould and the outside of the mould.

14. A mould according to claim 12 or claim 13 wherein the protrusion is formed by an element having a substantially circular cross-section, an axis of the protrusion being substantially perpendicular to the perimeter wall from which the protrusion extends.

15. A mould according to any of claims 12 to 14 wherein the protrusion is formed with an external profile having regions of differing external diameter.

16. A mould according to claim 15 wherein the protrusion has a first region of a first external diameter adjacent a second region of a second external diameter.

17. A tool comprising a sleeve portion which is adapted to have internal dimensions of at least the same as the largest dimensions of the regions of a corresponding protrusion.

18. A tool according to claim 17 wherein the tool further comprises a clamping means within the sleeve portion, adapted to clamp the said protrusion.

19. A tool according to claim 18 wherein the clamping means comprises two clamping portions which are moveable towards and away from each other substantially perpendicularly to an axis of the sleeve portion

20. A tool according to any of claims 17 to 19 having at least two sleeve portions wherein the sleeve portions are moveable relative to one another in at least one dimension.

21. A rack for storing casting cells comprising a column comprising two or more shelves arranged substantially vertically with respect to one another, each shelf

- 19 comprising at least one locating element for assisting the positioning of an object into a preferred position with respect to the shelf.

22. A rack according to claim 21 wherein each shelf has at least two locating elements.

23. A method of manufacturing moulded items comprising the steps of:

- directing a tool to engage with a protrusion of a pre-selected mould;

- directing the tool to move the mould to a pre-determined casting position within a casting cell;

- once the mould is in the casting position, activating one or more components of the casting cell in a casting cycle;

- when the casting cycle is complete, directing the tool to engage with the protrusion of the mould;

- directing the tool to move the mould to a pre-determined conveyor position with respect to a conveyor;

- directing the tool to separate the mould portions; and

- subsequently directing the tool to bring the mould portions together.

24. A method according to claim 23 effected in respect of more than one mould, and effected in an interleaved way.

25. A method according to claim 23 or claim 24 wherein the mould is arranged according to any of claims 12 to 16.

26. A method according to any of claims 23 to 25 wherein the tool is arranged according to any of claims 17 to 20.

27. A method according to any of claims 23 to 26 wherein the method further comprises a step of identifying a location of the mould within a storage area.

28. A method according to any of claims 23 to 27 further comprising steps of:

- providing a slip material to the mould by way of a port of the mould; and

- applying pressure to the mould for a pre-determined period to remove fluid from the mould.

29. A method according to any of claims 23 to 28 further comprising a step of tilting

5 the mould.