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    Ajay Parihar
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    The document describes rapid casting processes from WCM Europe that allow for tool-less manufacturing through 3D printed molds or sand cores. These hybrid investment and layer sand technology processes can produce castings from a variety of materials in as little as 5 days from CAD data, without the costs associated with hard tooling. The techniques enable design flexibility, validation of packaging and performance without cost commitment, and dramatic reductions in lead time and costs.

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    The document describes rapid casting processes from WCM Europe that allow for tool-less manufacturing through 3D printed molds or sand cores. These hybrid investment and layer sand technology processes can produce castings from a variety of materials in as little as 5 days from CAD data, without the costs associated with hard tooling. The techniques enable design flexibility, validation of packaging and performance without cost commitment, and dramatic reductions in lead time and costs.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as pdf or txt
    10 views17 pages

    Rpcastingsolutions

    Uploaded by

    Ajay Parihar
    The document describes rapid casting processes from WCM Europe that allow for tool-less manufacturing through 3D printed molds or sand cores. These hybrid investment and layer sand technology processes can produce castings from a variety of materials in as little as 5 days from CAD data, without the costs associated with hard tooling. The techniques enable design flexibility, validation of packaging and performance without cost commitment, and dramatic reductions in lead time and costs.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as pdf or txt
    of 17

    WCM Europe

    Basildon

    Rapid Prototype
    Casting Solutions

    Derek Bish
    WCM Europe

    Rapid Casting Process


    Tool-less Manufacturing

    • Total Design flexibility


    • No two components need to be
    manufactured the same allowing:
    • optimum component performance
    • packaging and production design validation
    • dramatic reduction in both cost and lead-times
    WCM Europe

    Rapid Casting Process


    Tool-less Manufacturing

    • Production intent material


    • No cost commitment to Hard tooling
    • Parts can be used for testing and
    production
    WCM Europe

    Hybrid Investment
    Process Steps

    • Day 1
    – CAD Data (stl, iges, proE, Catia, UG, Ideas)
    – Pattern build (Thermojet/Voxeljet)
    • Day 2 / 3
    – Add foundry methods
    – Ceramic medium added
    – Ceramic fired
    • Day 4 / 5
    – Cast
    – Mould broken out
    – Casting fettled and cleaned
    WCM Europe

    Hybrid Investment
    Voxeljet Lost
    Pattern
    WCM Europe

    Hybrid Investment
    Voxeljet Lost
    Pattern

    •850 X 450 X 500 build platform


    •PMMA with wax infiltration
    •Non-thermal (uses binder)
    •No support structure
    •0.1mm - 0.2mm layers
    •Build speed 12-48mm/hr
    •Minimal ash residue
    •Stable part
    Data Pattern built

    Finished Casting
    Vacuum
    Casting
    Process

    WCM Europe
    WCM Europe

    Hybrid Investment
    Vacuum Casting

    •300dia X 600 envelope •Up to 9 kg melt weight (Al)


    Layer Sand Technology
    Process Steps

    •Day 1
    •Model received
    •Data Modified
    •Stock added, methods, mould assembly
    •Day 4 / 5
    •Moulds Built (Prometal)
    •Day 6 / 7
    •Moulds Assembled
    •Cast and Fettle
    •Finished Casting
    WCM Europe
    Layer Sand Technology
    Prometal Sand Printing

    WCM Europe
    Layer Sand Technology
    Prometal Sand Printing

    •Uses conventional sand with furan-resin binder


    •1500 X 750 X 700 build platform
    •Build speed 14-20 mm/hr
    •Complex mould and cores
    WCM Europe
    Sand Printing Mould preparation

    Mould Breakout Finished Casting

    WCM Europe
    Rapid Casting Process

    • Accuracy +/- .15 Up to 125mm


    • No draft / taper
    • Undercuts
    • Complex designs
    • Thin Wall > 1mm (Hybrid Investment)
    • Cast Detail

    WCM Europe
    WCM Europe

    Materials
    • Traditional LM25 TF
    • Other Non Ferrous
    • Production materials e.g. LM24
    • Yellow Metals
    • Cast Iron
    • SG Iron
    • CGi
    • Stainless Steel (incl. Austenitic Grades)
    • Development materials
    WCM Europe
    WCM Europe
    WCM Europe

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