Multi-material inorganic 3D printed molds and cores can improve parts’ strength and design freedom while reducing carbon footprint.
Indirect additive manufacturing is an alternative way to produce metal parts by using foundry practices. This presentation will detail a novel method that uses binder jetting with different powders such as silica and steel to create a multi-material mold. This methodology gives the ability to have specific thermal conductivity at specific location to reduce hot spots. The reduction of hot spots enables geometries that are more complex and are said to be impossible via sand casting.
The methodology also reduces the mold’s weight. The molds or cores become a shell. The shell thickness is optimized by taking into account the metallostatic pressure and its own weight.
Furthermore, we have developed binder jetting 3D printer to additively manufacture molds and core with inorganic binder.
Commercial simulations software confirms material and location choices.
Multi-material molds have been 3D printed to confirm the methodology.
- Better understanding of binder jetting molds and cores, especially in multi-material.
- Design for additive manufacturing (DFAM) and cast parts that were said to be impossible.
- Simulate a cast of multi-material sand molds.