Design guidelines for plastic casting using 3D printing

Abstract

The main aim of the presented tests was to assess the possibility of using 3D printing and casting material to produce casting molds and prototypes, especially in production of existing models. The analysis was based on the assessment of dimensional accuracy and quality of the surface layer of a finished prototype and the intermediate elements made during the production process. The mold was made using the PolyJet Matrix additive technology, and then a silicone mold was cast which was used to prepare a finished sample for testing in accordance with the design assumptions. Based on the results of metrological measurements, the phenomenon of technological inheritance in terms of error transfer in the foundry industry was evaluated. The measurements obtained suggest that in case of casting process, the hereditary features are transferred from individual casting processes, which is especially prominent in the case of surface texture quality. This confirms the occurrence of the phenomenon of the so-called technological inheritance and the need to analyze it. The results of the tests can be a guide for technologists who design molds, core boxes, and casting models, concerning the corrections (shrinkage) that need to be introduced at the design stage in order to obtain a product (casting) of satisfactory dimensional accuracy and quality of the surface layer. The result can also be useful for casting materials reinforced with glass fiber, carbon fiber, which are common materials in 3D printing and textile industry.

The Influence of Printing Orientation on Surface Texture Parameters in Powder Bed Fusion Technology with 316L Steel

“…Rapid prototyping of tools used in conventional production technologies such as machining, casting [10][11][12], or injection moulding allows for immediate subsequent printing necessary after testing. Moreover, additive technologies enhance optimization of production and enable fast adaptation of new solutions.…”

Sustainable Additive Manufacturing: Mechanical Response of Polyethylene Terephthalate Glycol over Multiple Recycling Processes

“…Although the mechanical response of 3D printed parts seems to be inferior to that of other manufacturing methods, recycling polymers for use in AM applications shows potential for a circular economy. This is of importance considering that 3D printing is an industrial process that is already utilized in industrial applications such as in foundry [ 27 ].…”

Viscoelastic Properties of Cell Structures Manufactured Using a Photo-Curable Additive Technology—PJM

“…Due to the fact that 3D printing technologies differ both in terms of input material condition and layer binding method, the number of process parameters is variable, but the main ones include printing direction, layer thickness, laser speed and power, hatch distance, build chamber temperature etc. Mechanical properties and the dimension and shape accuracy of additive-shaped models is currently at such a high level that 3D printing technologies are used in such industries as foundry [ 12 , 13 ], jewelry, aviation and automotive [ 14 ], food and beverage, architecture, medicine [ 15 , 16 , 17 ] etc.…”