Is it true that the mold, right after binder jetting 3D printing, still has loose ceramic powder? How does the mold curing by the microwave furnace work? Does this process enable a nice surface finish for the final cast piece? Thanks!
From Foundry Lab: Typically, after printing, there is little green strength. Like most binder jetting systems, heat is used to set the binder. The final part has a surface finish between sand casting and diecasting.
Although I like the idea somewhat and admire your commitment, I have to say that the approach looks terrifying. The surface quality looks much worse than an average sand casting with this wall thickness, no localised feeding is provided and mechanical properties are likely to be far below standards with these slow cooling rates. The process cannot be used for more than demonstration parts, and it is very expensive for that, as I can achieve the same effect with a painted plastic print.
It depends on what you mean by “mass.” Die casting is going to be more cost-effective for high volumes. If the quantity of parts needed is in the hundreds, this is potentially a viable production solution. This article gets into that: www.additivemanufacturing.media/articles/foundry-lab-how-casting-in-a-day-will-improve-the-design-of-metal-parts-(includes-video)
@davincifpv3842 For the most part, yes, the mold is reusable. One exception might be if something about the cast part geometry requires the mold to be smashed to remove it. Barring that, yes.
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I talked to them at Formnext last year, it was unclear how many castings a single mold could go through.
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Is it true that the mold, right after binder jetting 3D printing, still has loose ceramic powder? How does the mold curing by the microwave furnace work? Does this process enable a nice surface finish for the final cast piece? Thanks!
From Foundry Lab: Typically, after printing, there is little green strength. Like most binder jetting systems, heat is used to set the binder. The final part has a surface finish between sand casting and diecasting.
Although I like the idea somewhat and admire your commitment, I have to say that the approach looks terrifying. The surface quality looks much worse than an average sand casting with this wall thickness, no localised feeding is provided and mechanical properties are likely to be far below standards with these slow cooling rates. The process cannot be used for more than demonstration parts, and it is very expensive for that, as I can achieve the same effect with a painted plastic print.
is this viable for mass production?
No, but still very cool. Is the mold reusable?
its basically for R&D, Testing purpose.
It depends on what you mean by “mass.” Die casting is going to be more cost-effective for high volumes. If the quantity of parts needed is in the hundreds, this is potentially a viable production solution. This article gets into that: www.additivemanufacturing.media/articles/foundry-lab-how-casting-in-a-day-will-improve-the-design-of-metal-parts-(includes-video)
@davincifpv3842 For the most part, yes, the mold is reusable. One exception might be if something about the cast part geometry requires the mold to be smashed to remove it. Barring that, yes.