DIY 3D printing of sand mold for metal casting
ฝัง
- เผยแพร่เมื่อ 15 ก.พ. 2023
- www.iro3d.com/ How to 3D print sand molds or cores for metal casting using Selective Powder Deposition (SPD)
This method was invented by Luis Trueba, Assistant Professor at Texas State University. - วิทยาศาสตร์และเทคโนโลยี
![[LIVE] : ONE ลุมพินี 63 วันนี้!! คู่เอก "ยอดภูผา vs โซเนอร์"](http://i.ytimg.com/vi/RGVmBsegKEI/mqdefault.jpg)
You're doing amazing work. Thank you for all the hard work you've put into this.
Good to have you back, hope things are good on your end after recent craziness.
It was neat seeing more footage of it working, and also this use case. I (and many others I’d imagine) would love to see more timelapses/prints even!
Always happy to see another iro3d video
Good work ❤
Офигенно. Вы большой молодец!
This is extremely promising
Have you considered releasing all this under some Open Source license?
Granted i’d like to buy one (one day where i have the money and space for this + a kiln etc) either way, *BUT* i feel like if you made a “Hackaday” page, and also just got more people tinkering/talking about it, that *combined with your existing experience and high quality products* could kind of put you in a position of where Prusa Research is now.
Granted your project at the end of the day, and great work is great work, but it FDM 3D Printing is to be learned from, adoption EXPLODES and designs are quickly evolved when something is Open Sourced.
Just “my 10 cents” I guess, keep up the amazing work!
Shell Sand? You mean Forbidden Brown Sugar?
are you heating the molds before casting? in which container and with what care you heat the steel
No, the mold or core from shell sand should not be heated before casting. The foundry heated the steel in their induction furnace.
Privet, quick question. Instead of depositing different powders with your awesome 3D printer, would it not make more sense to use "shell molding sand" and spread a thin layer like in a SLS machine to harden with a laser or IR light or something alike ? The sand is inert, the temp required to do this is way lower, no high power laser needed, the print time would be fast, accuracy should be good and the overall process and consumables and cheap and easily done at home. You would 3D print a metal cast mold and then simply cast the object out of whichever metal you choose to. It´s not directly a metal 3D print, you just print the mold but I think it would be more than good enough for many many applications.
Alternativly the shell mold sand only needs a low temp. to set, 200°C or so I think you have said it yourself, basically doable in a kitchen oven. Maybe the sand could be directly deposited by a FDM machine through a hot end instead, maybe not as a filament but as paste for example ? Am I onto something or is it a stupid idea ?
BTW huge fan of your work, genius idea and great implementation, your system is by far the best idea I have seen for metal 3D printed parts for a very very low price at a good quality.
Sorry I didn't notice your comment earlier. You have very interesting ideas. I think they would be worth trying. Also, feel free to contact me directly.
This seems to be crying out for a custom 3d pla printer where the walls are built with very thin pla and you then infill with the two types of sand.
Wouldn't that be the best of both worlds? It would give the accuracy and finish of pla but the ease of this method?
I don't quite understand how it could work. At what temperature would you burn out the PLA? Wouldn't it damage the shell sand binder? And what the thickness of the "very thin pla"? If it's more than the grain of the sand, then that would make the surface finish worse.
@@iro3d maybe this, th-cam.com/video/Zdyqsj9-7es/w-d-xo.html
Have you tried to make rings or jewelry with your machine?
No, I think for jewelry you would need a better surface finish and higher resolution.
Interesting solution. I was commenting on one of your previous videos about material selection. Unfortunately you said that low carbon (alloy) steels, especially in the range of AISI 1010-1030 are currently not supported. These materials are so important, because of their ferromagnetic properties. A lot of novel electromechanical devices rely on those materials and - as I've checked recently - other 3D additive metal manufacturing processes are also very poor in this regard (excluding powder bed fusion and direct energy deposition, which practically works with any kind of metal powder/wire, but very expensive).
In my opinion, using this method for creating the mold and subsequently casting with low carbon steel is feasible. My only problem is the coarse grain of the sand (400 micron is very large in my opinion, which in our application can create problems for reproducing small
The 400 micron sand is used only inside. The outside surface is poured with a finer sand. You might be able to use 75-100 microns fine powder. Or even smaller if you want to apply the binder after pouring. But for that you would need to find a spherical PTFE powder. I can explain the details by phone (or Telegram). Give me a call.
@@iro3d Thanks, that sounds great. For our purpuses 75-100 microns would be fine, since our current (resin) printer's resolution is 50.
As for contact and possible purchase, first we have to finish the current (mechanical) testing phase, we print the parts with a simple resin LCD 3D printer (which is cool, since standard resin is transparent, so we can check all the mechanical characteristics easily from the outside).
But for the final, electromechanical prototype (and probably small scale manufacturing) we have to use LC steel.
So based on the finalized mechanical design, we have to remodel (CAD) the parts with the final electromechanical elements in it.
Only after these 2 phases are finished can I concentrate on manufacturing, but based on your answer, I'm almost certain, that your solution will be the first to be considered. Especially if you can give us advice about steel casting, which we know nothing about...
Sounds good. Looking forward.
@@iro3d I have now some more experience, regarding available technologies for our low-alloy steel manufacturing needs and it is quite unpromising. Most of the commercial 3D printing services are available only for stainless steels (which are out of question for ferromagnetic applications) with no low-alloy steel printing options.
They recommend CNC machining instead (it has high undercuts, like internal cavities), but with CNC-machining I had to re-design my CAD model (basically cut almost all main parts by half), just so they can manufacture it (more precisely, to give me price quotation). It causes a lot of post-processing (e.g. metal bonding) since there is no functional reason to cut these parts. Also it significalty increase hydraulic risks (leakage).
Your solution - detailed in this video - seems much more promising. I've also checked your portal, especially the comparison of printing methods, which is a great source of knowledge, thank you! I think you can add another line to the table, detailing this method, like "Sand Mold SPD with metal casting". Based on the table I also think, that this method - albeit a bit more expensive - is superior to the others listed in the table.
I've also checked for available melting furnaces (especially induction-based, because of their performance) and found this:
www.inductotherm.com/products/mini-melt-furnaces/
I think, combining this with your printer, could be a great overall solution for printing needs, especially for those people or companies, who don't want to compromise regarding printing materials and strength of the product.
@@gucsog Thanks. I'll look into that furnace. BTW, how much does it cost? (I don't see any price on their website)