3D printing sand moulds cell

Demonstrators and highly complex metallic components combining two processes “near the shape”: additive and casting manufacturing to improve them in terms of design, properties and new functionalities. Combined with another BDIH active, sand moulds and prototypes made with steel, cast iron, or other base material (Ni, Al,…) could be supplied.

To increase the heat transfer, the manufacturing of cores is performed with inner reticular structure, by performing location of integrated metallic inserts of other materials; by application of different coatings which provoke the dissipation

Optimization of additive manufacturing process by means of optimized deposition trajectories, optimized drop size and flow profiles; and coupled to the deposition trajectory to produce “stair step free” sand moulds. By reducing the steps in the mould, the roughness of the manufactured components is reduced.

-New non-conventional filling (helical) and/or feeding systems (parabolic risers, conical helix) with optimized designs made by simulation (Quikcast, Procast, Kassandra) will be tested. -It makes easier the sensorization for thermal monitoring, dynamic, gases, … -Innovation in the layout of mould, partition lines, single moulding, etc.

Design/redesign of highly complex prototypes to be manufactured by casting in 3D printed sand moulds, minimizing subsequent machining operations. The cell allows to perform complex geometries impossible to be manufactured by traditional moulding system: very thin thicknesses, bio-inspired designs, lightened designs, topologic optimization, reticular structures, …

Manufacturing of shell moulds (thin thicknesses). In this way, complex geometries with high solidification rates could be combined. That means, microstructures with better properties and functionalities will be obtained