3D print durable, accurate patterns.
Sand casting patterns can be 3D printed with PolyJet or FDM Technology for substantial savings in cost, labor and time, ultimately speeding new product development.
The green sand casting process uses a mold made by pressing a pattern into a sand mixture. The pattern leaves a cavity into which molten metal is poured. This process works well for low–volume production. With automated equipment, it can be efficient for high–volume production. Three common types of sand casting patterns are:
Producing sand molds and cast metal parts is relatively straightforward and suitable for automated methods that can reduce cycle time and labor. However, fabricating the patterns is often difficult, time-consuming, and expensive. The most common approach is to produce aluminum patterns using CNC machining. The biggest problems with this approach are the high cost and lengthy lead time.The potential for problems, such as incorrect shrink compensation and design flaws, means the initial pattern often must be redone, which adds to the expense and lead time. It is not usually practical to machine the intricate gate and runner systems on CNC machines because testing is required to finalize the design. Instead, the gate and runner system is cut from Ren board or similar material and then hand-carved and sanded to the finished shape. Constructing the gating system adds expense and lead time.
Because of the problems associated with traditional pattern production, foundries have long been interested in 3D printing (also called additive manufacturing). With 3D printing systems available from Stratasys, foundries can fabricate patterns with either inkjet-based technology or FDM Technology. This results in substantial cost savings, labor, and time, ultimately speeding up new product development.
Pour the molten metal in the cavity. Once it cools, it can be removed and finished.
|CNC Matchplates||$5,000||3-4 weeks|
|FDM Tooling Matchplates||$2,000||1.5 weeks|
|SAVINGS||$3,000 (60%)||1.5-2.5 weeks (37%-62%)|