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Integrating additive manufacturing (AM) tools in traditional mold-making provides complex yet affordable sand molds and cores. AM processes such as selective laser sintering (SLS) and Binder jetting three-dimensional printing (BJ3DP) are widely used for patternless sand mold and core production. This study aims to perform an in-depth literature review to understand the current status, determine research gaps and propose future research directions. In addition, obtain valuable insights into authors, organizations, countries, keywords, documents, sources and cited references, sources and authors.

This study followed the systematic literature review (SLR) to gather relevant rapid sand casting (RSC) documents via Scopus, Web of Science and EBSCO databases. Furthermore, bibliometrics was performed via the Visualization of Similarities (VOSviewer) software.

An evaluation of 116 documents focused primarily on commercial AM setups and process optimization of the SLS. Process optimization studies the effects of AM processes, their input parameters, scanning approaches, sand types and the integration of computer-aided design in AM on the properties of sample. The authors performed detailed bibliometrics of 80 out of 120 documents via VOSviewer software.

This review focuses primarily on the SLS AM process.

A SLR and bibliometrics using VOSviewer software for patternless sand mold and core production via the AM process.

This study aims to improve the acceleration in the additive manufacturing (AM) process. AM tools, such as extrusion heads, jets, electric arcs, lasers and electron beams (EB), experience negligible forces. However, their speeds are limited by the positioning systems. In addition, a thin tool must travel several kilometers in tiny motions with several turns while realizing the AM part. Hence, acceleration is a more significant limiting factor than the velocity or precision for all except EB.

The sawtooth (ST) scanning strategy presented in this paper minimizes the time by combining three motion features: zigzag scan, 45º or 135º rotation for successive layers in G00 to avoid the CNC interpolation, and modifying these movements along 45º or 135º into sawtooth to halve the turns.

Sawtooth effectiveness is tested using an in-house developed Sand AM (SaAM) apparatus based on the laser–powder bed fusion AM technique. For a simple rectangle layer, the sawtooth achieved a path length reduction of 0.19%–1.49% and reduced the overall time by 3.508–4.889 times, proving that sawtooth uses increased acceleration more effectively than the other three scans. The complex layer study reduced calculated time by 69.80%–139.96% and manufacturing time by 47.35%–86.85%. Sawtooth samples also exhibited less dimensional variation (0.88%) than zigzag 45° (12.94%) along the build direction.

Sawtooth is limited to flying optics AM process.

Development of scanning strategy for flying optics AM process to reduce the warpage by improving the acceleration.