P.M. Dickens, R. Stangroom, M. Greul, B. Holmer, K.K.B. Hon, R. Hovtun, R. Neumann, S. Noeken and D. Wimpenny
The Tooling and Casting subgroup of the European Action on Rapid Prototyping (EARP) has undertaken a project to investigate the problems associated with using rapid prototype…
Abstract
The Tooling and Casting subgroup of the European Action on Rapid Prototyping (EARP) has undertaken a project to investigate the problems associated with using rapid prototype models as sacrificial patterns for investment casting. The accuracy and surface finish of the models and the castings were also assessed so that a comparison could be made. Models from each process were manufactured by different members of EARP and then three foundries were each given a set of models to convert to castings. Observes that one of the oldest metal manufacturing techniques, which dates back to 4000‐6000 BC, is being used with one of the most modern ‐ rapid prototyping.
Details
Keywords
Munish Chhabra and Rupinder Singh
This paper seeks to review the industrial applications of state‐of‐the‐art additive manufacturing (AM) techniques in metal casting technology. An extensive survey of concepts…
Abstract
Purpose
This paper seeks to review the industrial applications of state‐of‐the‐art additive manufacturing (AM) techniques in metal casting technology. An extensive survey of concepts, techniques, approaches and suitability of various commercialised rapid casting (RC) solutions with traditional casting methods is presented.
Design/methodology/approach
The tooling required for producing metal casting such as fabrication of patterns, cores and moulds with RC directly by using different approaches are presented and evaluated. Relevant case studies and examples explaining the suitability and problems of using RC solutions by various manufacturers and researchers are also presented.
Findings
Latest research to optimize the current RC solutions, and new inventions in processing techniques and materials in RC performed by researchers worldwide are also discussed. The discussion regarding the benefits of RC solutions to foundrymen, and challenges to produce accurate and cost‐effective RC amongst AM manufacturers concludes this paper.
Research limitations/implications
The research related to this survey is limited to the applicability of RC solutions to sand casting and investment casting processes. There is practically no implication in industrial application of RC technology.
Originality/value
This review presents the information regarding potential AM application – RC, which facilitates the fabrication of patterns, cores and moulds directly using the computer‐aided design data. The information available in this paper serves the purpose of researchers and academicians to explore the new options in the field of RC and especially users, manufacturers and service industries to produce casting in relatively much shorter time and at low cost and even to cast complex design components which otherwise was impossible by using traditional casting processes and CNC technology.
Details
Keywords
Younss Ait Mou and Muammer Koc
This paper aims to report on the findings of an investigation to compare three different three-dimensional printing (3DP) or additive manufacturing technologies [i.e. fused…
Abstract
Purpose
This paper aims to report on the findings of an investigation to compare three different three-dimensional printing (3DP) or additive manufacturing technologies [i.e. fused deposition modeling (FDM), stereolithography (SLA) and material jetting (MJ)] and four different equipment (FDM, SLA, MJP 2600 and Object 260) in terms of their dimensional process capability (dimensional accuracy and surface roughness). It provides a comprehensive and comparative understanding about the level of attainable dimensional accuracy, repeatability and surface roughness of commonly used 3DP technologies. It is expected that these findings will help other researchers and industrialists in choosing the right technology and equipment for a given 3DP application.
Design/methodology/approach
A benchmark model of 5 × 5 cm with several common and challenging features, such as around protrusion and hole, flat surface, micro-scale ribs and micro-scale long channels was designed and printed repeatedly using four different equipment of three different 3DP technologies. The dimensional accuracy of the printed models was measured using non-contact digital measurement methods. The surface roughness was evaluated using a digital profilometer. Finally, the surface quality and edge sharpness were evaluated under a reflected light ZEISS microscope with a 50× magnification objective.
Findings
The results show that FDM technology with the used equipment results in a rough surface and loose dimensional accuracy. The SLA printer produced a smoother surface, but resulted in the distortion of thin features (<1 mm). MJ printers, on the other hand, produced comparable surface roughness and dimensional accuracy. However, ProJet MJP 3600 produced sharper edges when compared to the Objet 260 that produced round edges.
Originality/value
This paper, for the first time, provides a comprehensive comparison of three different commonly used 3DP technologies in terms of their dimensional capability and surface roughness without farther post-processing. Thus, it offers a reliable guideline for design consideration and printer selection based on the target application.
Details
Keywords
K. Dotchev and S. Soe
The main objective of this paper is to analyse all stages of the CastForm™ polystyrene (CF) pattern fabrication process, identify the reasons leading to inferior quality, and…
Abstract
Purpose
The main objective of this paper is to analyse all stages of the CastForm™ polystyrene (CF) pattern fabrication process, identify the reasons leading to inferior quality, and outline techniques for its improvement and reduction of failures.
Design/methodology/approach
This paper describes rapid manufacturing of patterns for shell or flask investment casting using the laser sintering (LS) technique with CF material. The process involves data preparation, LS fabrication of a “green” part, cleaning, and wax infiltration. All process stages are equally important for successful project completion in terms of pattern quality and delivery time. A failure at any stage requires a part or pattern to be produced again, which would incur additional time and cost.
Findings
The conducted experiments show how the CF material strength varies at different process stages and temperatures. Cleaning and wax infiltration are considered the main reasons for part distortion and breakage.
Originality/value
The paper proposes a new approach for wax infiltration. Deformation and breaking of unsupported features could be reduced or eliminated by introducing a supporting structure under these features.
Details
Keywords
Sunpreet Singh and Rupinder Singh
This paper aims to review the industrial and biomedical applications of state-of-the-art fused deposition modelling (FDM)-assisted investment casting (FDMAIC). Brief literature…
Abstract
Purpose
This paper aims to review the industrial and biomedical applications of state-of-the-art fused deposition modelling (FDM)-assisted investment casting (FDMAIC). Brief literature survey of methodologies, ideas, techniques and approaches used by various researchers is highlighted and use of hybrid feedstock filament-based pattern to produce metal matrix composite is duly discussed.
Design/methodology/approach
Pattern replica required for investment casting (IC) of biomedical implant, machine parts, dentistry and other industrial components can be directly produced by using FDM process is presented. Relevant studies and examples explaining the suitability of FDMAIC for various applications are also presented.
Findings
Researches to optimize the conventional IC with FDM solutions and develop new hybrid feedstock filament of FDM done by researchers worldwide are also discussed. The review highlights the benefit of FDMAIC to surgeons, engineers and manufacturing organizations.
Research limitations/implications
The research related to this survey is limited to the suitability and applicability of FDMAIC.
Originality/value
This review presents the information regarding potential IC application, which facilitates the society, engineers and manufacturing organizations by providing variety of components for assisting FDM. The information reported in this paper will serve doctors, researchers, organizations and academicians to explore the new options in the field of FDMAIC.
Details
Keywords
Brian N. Turner and Scott A Gold
The purpose of this paper is to critically review the literature related to dimensional accuracy and surface roughness for fused deposition modeling and similar extrusion-based…
Abstract
Purpose
The purpose of this paper is to critically review the literature related to dimensional accuracy and surface roughness for fused deposition modeling and similar extrusion-based additive manufacturing or rapid prototyping processes.
Design/methodology/approach
A systematic review of the literature was carried out by focusing on the relationship between process and product design parameters and the dimensional and surface properties of finished parts. Methods for evaluating these performance parameters are also reviewed.
Findings
Fused deposition modeling® and related processes are the most widely used polymer rapid prototyping processes. For many applications, resolution, dimensional accuracy and surface roughness are among the most important properties in final parts. The influence of feedstock properties and system design on dimensional accuracy and resolution is reviewed. Thermal warping and shrinkage are often major sources of dimensional error in finished parts. This phenomenon is explored along with various approaches for evaluating dimensional accuracy. Product design parameters, in particular, slice height, strongly impact surface roughness. A geometric model for surface roughness is also reviewed.
Originality/value
This represents the first review of extrusion AM processes focusing on dimensional accuracy and surface roughness. Understanding and improving relationships between materials, design parameters and the ultimate properties of finished parts will be key to improving extrusion AM processes and expanding their applications.
Details
Keywords
Dilip Sahebrao Ingole, Abhay Madhusudan Kuthe, Shashank B. Thakare and Amol S. Talankar
The purpose of this paper is to apply rapid prototyping (RP) philosophy as a technology transfer in industries to take its time and cost‐effective advantages for development of…
Abstract
Purpose
The purpose of this paper is to apply rapid prototyping (RP) philosophy as a technology transfer in industries to take its time and cost‐effective advantages for development of rapid tooling (RT).
Design/methodology/approach
Experimentations are performed for development of RT for sand casting, investment casting and plastic moulding applications.
Findings
This paper reports the procedures developed for manufacture of production tooling using RP. A cost/benefit model is developed to justify implementation of RP as a technology transfer in industries.
Research limitations/implications
The examples are limited to parts build by fused deposition modelling RP process. However, the concepts experimented may be applied for other RP processes.
Practical implications
RP has proved to be a cost‐effective and time‐efficient approach for development of RT, thereby ensuring possibility for technology transfer in casting as well as plastic industries.
Originality/value
This is the pioneer attempt towards quantifying RP benefits, in view of technology transfer. This paper presents original case studies and findings on the basis of experimentations performed in foundries.