Additive Manufacturing of Complex Ceramic Cores for Investment Casting

Purpose and goal

This prestudy was focused on application of 3D printed ceramic cores and plastic patterns for precision casting of aluminium parts. The research had 2 main objectives: 1-Evaluate the possibility of using AM for producing casting cores and patterns with high dimensional accuracy and low surface finish. 2-Evaluate the environmental impacts of core and pattern production by AM; and compare it with the conventional ways. The concept wast tested in a real casting trial at Ventana Hackås and a life cycle assessment was carried-out.

Expected results and effects

3D printed ceramic cores and plastic patterns satisfy requirements on dimensional accuracy and surface finish for precision casting with plaster moulds. Surface finish of 3D printed cores are ~50% better than the conventional plaster cores. However, casting results show that the strength of the 3D printed cores require further improvement. In addition, 3D printed plastic patterns were successfully utilized to fabricate plaster moulds. For production series below 15 pieces, the LCA indicates a lower environmental impact when using 3D printed ceramic core and plastic patterns.

Planned approach and implementation

This prestudy was a collaboration between Swerea IVF and Ventana Hackås AB. Swerea IVF contributed with knowledge in different additive manufacturing technologies; and Ventana Hackås, with expertise in precision casting of complex aluminium parts. To demonstrate the proposed concept, a lamp holder component was casted using 3D printed ceramic cores and 3D printed plastic patterns. A screening life cycle assessment was carried-out (by Swerea IVF) to gain knowledge of the environmental impact of the proposed manufacturing route.