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Speaking of Precision

Speaking of Precision is a knowledge preservation and thought leadership blog covering the precision machining industry, its materials and services. With over 36 years of hands on experience in steelmaking, manufacturing, quality, and management, Miles Free (Milo) Director of Industry Research and Technology at PMPA helps answer "How?" "With what?" and occasionally "Really?"

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How Additive Manufacturing Could Increase Competitiveness of Investment Casting

Posted July 24, 2012 12:00 AM by Milo

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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Re: How Additive Manufacturing Could Increase Competitiveness of Investment Casting

07/25/2012 3:45 PM

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.

The question remains......given all the consumer gadget engineering why are we so far behind in this technology? I can see the day when the entire machinery infrastructure will be 'printed'.......that includes simple machines like cars and aircraft whose structural integrity would be far improved!

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Re: How Additive Manufacturing Could Increase Competitiveness of Investment Casting

07/28/2012 6:15 PM

3D printing can't "currently" - produce the required casting metallurgical properties in most critical applications such as gas turbine blade, guide vanes, nozzles and ducts but 3D printing the sacrificial ceramic shell is an entirely different story.....

3d prototypes are usually more dimensionally accurate than the castings they represent so it's safe to assume the ceramic shells will be very accurate as well which will render the wax patterns, ceramic cores and pattern dies obsolete! $$

"You can just use the CAD model to play with your shell's shrink factor, gate size and placement until you get it right."

This is a huge deal because approximately 25% of the investment casting process goes away - but the process has to (1) work as advertised, (2) get approved and (3) be cheaper than the current method - which based on my experience will probably take about a decade to implement in the aerospace community although automotive may see it in a year or two.

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