Sustainable manufacturing of 3D printed sandmolds and cores

Purpose and goal

The overall aim project was to create knowledge about the use of printed cores in existing casting processes. The technology is new, and therefore there were several issues that needed to be investigated. The project has investigated how well a printed detail matches the drawing. For better simulation results, the thermal conductivity properties of printed molds have been investigated. Sand from a Swedish manufacturer is now used in one of the foundry companies. An educational concept has been developed and experiences from users have been compiled.

Expected results and effects

Dimensional accuracy - the examined printers mostly stay within their specified tolerances, but everyone of them have also shown occasional deviations. Printer sand´s impact on the green sand - a weak impact; the effects are less than expected Guidelines for designers have been summarized, which should provide better knowledge about cast iron construction Printed molds thermal conductivity has been measured. The data will give more reliable simulation results. One of the printer users has replaced German quartz sand with Swedish sand. Their casting process is adapted to Swedish.

Planned approach and implementation

For an evaluation of the printers´ dimensional accuracy, a sample geometry was designed that was printed in all Swedish printers, after which they were measured. Evaluation of the printer sand´s impact on the foundry´s other sand systems was performed by mixing printer sand in production sand and property measurements immediately or after a period. Swedish sand has been tested and replaced with the German sand (recommended by the printer supplier). The thermal conductivity of the printed molds has been evaluated through practical casting tests with temperature logging in the molds.