AN INTRODUCTION TO RAPID CASTING: DEVELOPMENT AND INVESTIGATION OF PROCESS CHAINS FOR SAND CASTING OF FUNCTIONAL PROTOTYPES

Abstract

This paper discusses the results obtained from studies on different Rapid Tooling process chains in order to improve the design and manufacture of foundry equipment that is used for sand casting of prototypes in final material. These prototypes are intended for functional and pre-production tests of vehicles. The Three Dimensional Printing process is used as core technology. Subsequently, while considering aspects such as time, cost, quality (accuracy and surface roughness), and tool life, a framework is presented for the evaluation and selection of the most suitable process chain in accordance with specific requirements. This research builds on an in-depth characterisation of the accuracy and repeatability of a 3D printing process.