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Investment casting is a process that creates
complex featured parts in volumes in
competition with precision machining.

(Investment
cast parts are used in aerospace, medical, and munitions applications.)
Investment casting
is also called the lost wax process. A major constraint is the manufacture of
the molds needed for this process.

Large Area Maskless Photopolymerization (LAMP),
is a new technology being proven by Researchers at Georgia
Tech. This high-resolution digital process builds the mold from CAD
files, layer by layer, by projecting bitmaps of ultraviolet light onto a
mixture of photosensitive resin and ceramic particles, and then selectively
curing the mixture to a solid.
A
high precision kind of 3-D printing, this technique places one
100-micron layer on top of another until the structure is complete. After the
mold is formed, the cured resin is removed through binder burnout and the
remaining ceramic is sintered in a furnace. The result is a fully ceramic
structure into which molten metal - such as nickel-based superalloys or
titanium-based alloys - are poured, producing a highly accurate casting.
This
direct digital method eliminates machining of tools and dies to manufacture
molds, eliminating weeks of lead time as well as costs.
While
it might be easy to shrug this off as mere 'rapid prototyping'- the fact is
that this technology could enable direct design to manufacturing.
Parts photo.
Casting Process Diagram.
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