Utilization of 3D Printed Materials in Expendable Pattern Casting Process

Abstract

While lost foam casting process offers advantages of producing complex parts without the needs of parting line, draft and core, this process requires long lead time and only works for high volume applications due to the tooling requirements. With recent developments of 3D printing technology, the limitations of this process can be mitigated. Utilization of 3D printed materials instead of foam will allow the production of pattern materials at lower cost and shorter lead time, and also, low-volume production. The objective of this study was to explore the feasibility of producing cast parts using expendable casting process with 3D printed materials (PLA, ABS, and PVA) as patterns. These materials were printed in a shape of fluidity spiral with different sizes and infill designs, and were then poured with A356.0 Aluminum. Results showed that this process can be used as an alternative method to produce cast aluminum components.