3d printing for sand castings

J

jclyma

Plastic

Joined

Dec 15, 2013

Location

S.E. Michigan

• Jan 10, 2014

• #1

I started a new job a few weeks ago at a company that uses additive manufacturing to create casting molds from sand without tooling. Curios if it is known out there that besides metal and plastics you can also print sand molds. It is fun to be able to create castings that need no draft

 

kapps

Cast Iron

Joined

Sep 17, 2007

Location

Orlando, FL

• Jan 10, 2014

• #2

Yeah it's a really cool thing. I learned about them after we did some testing on using plain old zcorp material and casting aluminum in it. Worked out really well. Then we realized there were machines and materials specifically meant for casting into.

 

W

will gilmore

Aluminum

Joined

Feb 6, 2007

Location

New York City

• Jan 10, 2014

• #3

No draft seems like the least of it. What about no cores? Lets see some pictures.

 

C

CBlair

Diamond

Joined

Sep 23, 2002

Location

Lawrenceville GA USA

• Jan 11, 2014

• #4

jclyma said:

I started a new job a few weeks ago at a company that uses additive manufacturing to create casting molds from sand without tooling. Curios if it is known out there that besides metal and plastics you can also print sand molds. It is fun to be able to create castings that need no draft

Click to expand...

What machines are you using, I know of two manufacturers but I am sure there are others. Also the forum rules state you must post your location, if you dont you will be subject to being cut off.

Charles

 

J

jclyma

Plastic

Joined

Dec 15, 2013

Location

S.E. Michigan

• Jan 11, 2014

• #5

Thanks Charles,
I want to make it clear that I am not trying to sell anything or promote the company that I work for. Below is a link to a video that shows exactly how it works.
I have been in the casting industry in S.E. Michigan for 27 years and have experience designing and casting molds using this process for Ford in the past. I am having fun with the opportunity to create castings that would be nearly impossible using traditional sand casting or permanent molds. A similar process is used for investment casting by creating a part from wax using the same type of technology.

Sand | ExOne

my link takes you to the page then click on "Sand printing process"

-Jeff

 

C

CBlair

Diamond

Joined

Sep 23, 2002

Location

Lawrenceville GA USA

• Jan 11, 2014

• #6

Thanks Jeff, I know how it works I just wondered whos equipment was chosen. I have not been in the industry as long as you, in fact I worked at an Iron foundry in NC for only two years but I learned a lot there and think this technology really has a place in the future. Glad to know you are in it and willing to share with us a bit.

Is the company you are working for in a position to do work for small orders? I would be happy to speak to you about it more, I will send you a private message.

Charles

 

B

bryan_machine

Diamond

Joined

Jun 16, 2006

Location

Near Seattle

• Jan 11, 2014

• #7

It's been pretty well known since at least 2002 when I funded a race engine project that bought one to make flasks for casting very low production (think 4 parts in a run) engine parts. Big win when things like oil pump impellors have to be revved with every engine build.

In fact, until the full metal sintering machines became commercially available (5 years ago?) it seemed that printing flasks for castings was by far the greatest practical use for 3D printing.

Can the ExOne process makes flasks suitable for cast iron, steel, etc.?

 

J

jclyma

Plastic

Joined

Dec 15, 2013

Location

S.E. Michigan

• Jan 12, 2014

• #8

Yes ExOne molds are used for any material I know if that can be cast in sand. They have a couple media options for printing molds depending on the geometry and material. When I get the opportunity I will take some pictures, right now all the casting and printing work in our facility is sensitive and not something I am allowed to share. If the work load lightens I have plans to do some testing with stuff like sprues and gating shapes that reduce turbulence that we cannot make with traditional molding.
Jeff

 

M

Miguels244

Diamond

Joined

Mar 27, 2011

Location

Denver, CO USA

• Jan 23, 2014

• #9

ExOne also has a process that builds a green sinter out of stainless. The green is fired then infused with (typically) bronze.

 

M

Miguels244

Diamond

Joined

Mar 27, 2011

Location

Denver, CO USA

• Jan 25, 2014

• #10

They also mention a glass process.