See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/233670794

A novel lattice structure for SL investment casting patterns

Article  in  Rapid Prototyping Journal · July 2009

DOI: 10.1108/13552540910979776

CITATIONS READS
30 651

3 authors:

Sadegh Rahmati Yousef Norouzi

Islamic Azad University Tehran Science and Research Branch Independent
44 PUBLICATIONS   550 CITATIONS    1 PUBLICATION   30 CITATIONS   

SEE PROFILE SEE PROFILE

Yousef Hojjat
Tarbiat Modares University
89 PUBLICATIONS   792 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Advanced Manufacturing Technology, Additive Manufacturing, Rapid Prototyping, Rapid Tooling, Rapid Manufacturing View project

Medical Additive Manufacturing Technologies View project

All content following this page was uploaded by Sadegh Rahmati on 20 September 2014.

The user has requested enhancement of the downloaded file.

 A novel lattice structure for SL investment
casting patterns
Yousef Norouzi
Mechanical Engineering Department, Tarbiat Modares University, Tehran, Iran
Sadegh Rahmati
Centre of Advanced Manufacturing Technology, University of Imam Hussain, Tehran, Iran, and
Yousef Hojjat
Manufacturing Engineering Group, Tarbiat Modares University, Tehran, Iran

Abstract
Purpose – The purpose of this paper is to present the study of octagonal lattice structure for investment casting stereolithography (SL) patterns, and
compare it with the former hexagonal structure (of the QuickCast 2.0 build style). This research aims to introduce a new internal lattice structure for
investment casting SL patterns.
Design/methodology/approach – Applying 3D-coupled thermal-mechanical finite element analysis; magnitudes of exerted hoop stresses on ceramic
shell (during burnout stage) have been computed. As an experimental observation of stress evaluation for cylindrical hexagonal and octagonal models,
magnitudes of hoop and axial strains have been evaluated by installing self-temperature compensation strain gauges. In addition, practical results have
been obtained by the real-time strain gauging of the cylindrical models during the heating process up to 1008C.
Findings – The performance of SL pattern depends on several factors including the void ratio, drainage ability, dimensional accuracy, and burnout
ability (ability of burning out the model without ceramic shell cracking). Numerical results for new octagonal structure indicate that, there is a 62 percent
reduction in maximum hoop stresses exerted on the ceramic shell. Moreover, a significant reduction of strain has been observed in both hoop and axial
strains applying strain-gauging analysis (near 50 percent reduction). Besides, the obtained void ratio of the QuickCast 2.0 hexagonal and the new offset
octagon structures are 90 and 95 percent, respectively. Deductive investigation has been carried out for explaining the role of the other influencing
factors. The 49 percent reduction of internal mass expresses the probability of dimensional accuracy improvement for the octagonal structure.
Research limitations/implications – Several deductive investigations indicate the probability of better performance for the influencing factors
including void ratio, dimensional accuracy and drainage ability of the new octagonal structure. However, the main scope of the paper is to compare the
performance of models during burnout stage (the magnitudes of exerted stresses and strains on ceramic shell). Therefore, a more analytical and
practical approach will be a good future research for other mentioned factors.
Practical implications – This research aims to address the main problem, which is the shell cracking; it is essential to have more practical
investigations in other concepts that are not mentioned here though. Despite of that, the new octagonal structure will be a good replacement for former
hexagonal structure, ensuring the casting foundries for using the SL patterns.
Originality/value – A new generation of internal structure (or a new build style) for investment casting SL patterns is presented here. The significant
reduction of critical loadings on ceramic shell will ensure investment casting foundries for using SL patterns, which are by an octagonal internal
structure.

Keywords Rapid prototyping, Strain measurement

Paper type Research paper

1. Introduction of burning the patterns out of the ceramic shell caused a

Since the early days of stereolithography (SL), investment
casting foundries have been using prototype patterns built on
SL apparatus (SLA) machines. These early attempts at using
the models as sacrificial pattern were very haphazard. The
models were built using a solid build style, and so the process
The current issue and full text archive of this journal is available at
www.emeraldinsight.com/1355-2546.htm
considerable amount of thermal expansion, thus causing the
shell to crack (because the coefficient of thermal expansion –
CTE – for thermoset epoxy material is higher than the CTE
of ceramic material).
By using SLA machines, it was possible to generate patterns
at a fraction of the cost and time of traditional lost wax
method, so this would require the development of a new way
of using the SL patterns. At this time, a new resin was being
developed by Ciba-Giegy, now Vantico. This was an epoxy
resin, which had a much lower viscosity. To ensure the

Rapid Prototyping Journal

15/4 (2009) 255– 263 Received: 17 March 2008
q Emerald Group Publishing Limited [ISSN 1355-2546] Revised: 19 July 2008, 7 November 2008, 27 January 2009
[DOI 10.1108/13552540910979776] Accepted: 25 February 2009

255
 A novel lattice structure for SL investment casting patterns
Yousef Norouzi, Sadegh Rahmati and Yousef Hojjat
patterns built on the SLA machines had yield rate, the
patterns had to be much weaker to allow the burnout to occur
more easily and to eliminate the expansion of the pattern.
This would mean that creating a new build style, which would
create a series of interlinked voids, thus making a quasi-
hollow part, and with low viscosity, which would burn away
easily. This new build style, named QuickCast 1.0.
QuickCast, was a major leap in the direction of rapid
casting, although through time, this build style, which
originally consisted of triangular geometry, went through
two more development stages. This involved changing the
geometry of the build style, the first one being QuickCast 1.1
that changed the build style from triangular to square, the
second one changing the build style from square to an offset
hexagon, this was called QuickCast 2.0 (Tromans, 2003).
The QuickCast 2.0 build style is a mathematical algorithm
that will automatically hollow a solid SL geometry with a
“honeycomb” structure inside, removing up to 90 percent of
the mass (3D Systems Co., 2002).
2. Background and hypothesis
Essentially, the original structures for SL patterns was the
combination of two identical levels with the second level being
offset from the first to allow for the draining of the uncured
resin from the model. These levels are then repeated within
the part until the model is completed, and for QuickCast 1.0
and 1.1, the main frames were triangular and square.
QuickCast 2.0 was built in three levels, with each successive
level being identical to the one beneath, but rotated through
1208 (Figure 1; Hague and Dickens, 2001).
The prior investigations for designing lattice structures for
SL patterns indicate that the triangular and square structures,
because of their structural identity, were improving the
strength of model and transmitting bigger expansion to the
ceramic shell, during the burnout stage, causing the ceramic
shell to crack. Simple finite element (FE) analysis has
indicated that the maximum stress in the ceramic shell occurs
at around 65-708C temperature range (glassy region for SL
5170 resin; Hague and Dickens, 2001). Therefore, the main
purpose was designing a new structure, in which the model
should collapse inside of itself, before reaching the glass
transition temperature of resin. Another major problem with
Figure 1 Illustration of three levels for QuickCast 2.0 offset hexagon
structure
First level Second level Third level
All three levels Close-up isometric view
256
Rapid Prototyping Journal
Volume 15 · Number 4 · 2009 · 255 –263
original build styles concerns the inability to achieve complete
drainage of uncured resin because of the closed enclosures
generated in theses structures. By creating the QuickCast 2.0
internal structure most of the mentioned problems were
solved somehow.
Looking through the development of internal lattice
structures for SL patterns, it is found that there is a planar
connection between structural levels in the former triangular
and square structures. On the other hand, structural levels are
joined by point contact in offset hexagonal lattice. Because of
sudden change of section areas, every contact point is a stress
concentration region. Therefore, it is possible to produce a
much weaker pattern by increasing the contact regions to
deform easily in burnout stage. In addition, the new version of
internal structure should have a higher void ratio and better
drainage characteristics.
In this paper, a new lattice structure is introduced for
supporting this supposition. There are two main differences
between the conventional hexagonal and novel octagonal
structures. First of all, the new structure is based on an
octagon and with different patterns for making each identical
level. By comparing Figures 1-3, this is recognizable. The new
SL build style for investment casting is based on an octagon
and is constructed in three levels (which then are repeated,
like the former hexagon structure). The three levels of this
structure comprised individual sides of an octagon, with each
successive level being identical to the one beneath, but rotated
1208. Figure 2 shows the three identical levels of the structure.
In the second place, another difference is regarding the new
structural unit cells, which are used to form each level, which
is named as bridge-like unit cells. Sudden change in cross-
sectional area leads to a higher magnitude of stress
concentration in these structural units. Therefore, the final
structure will be weaker enough than former ones to collapse
easily during burnout stage. This new unit cell is shown in
Figure 4.
Figure 2 Three levels of new offset octagon structure
First level Second level Third level
Figure 3 New structure, stacking of three levels, close-up isometric,
and full isometric view
Stacking of Close-up isometric Full isometric
three levels view view
 A novel lattice structure for SL investment casting patterns Rapid Prototyping Journal
Yousef Norouzi, Sadegh Rahmati and Yousef Hojjat Volume 15 · Number 4 · 2009 · 255 –263

Figure 4 The changing of the structural unit cells
Stress
concentration
regoins
Exbudel
3. Burnout ability
Many studies have been carried out to understand what
happens in the burnout stage, which causes the ceramic shell
to crack. Most of the time, this is achievable by a 2D
symmetrical FE analysis. Nevertheless, because of the 3D
geometry of the octagonal and hexagonal structures it was not
possible to have a simple 2D analysis. Cylindrical models are
used to compare the behaviour of the structures during the
burnout stage. The dimensions of the internal links and
thickness of ceramic shell (3 mm) are the same for both of
the hexagon and octagon structures, and without any change
during the numerical analysis. The cylindrical shells have
more strength against outer pressures; therefore, the results of
this model could be applicable for other forms of SL patterns.
Quarter models are used for decreasing the time of analyses,
which is shown in Figure 5.
Because the material properties of epoxy as a thermoset resin
changes with temperature, for simulating the burnout stage, it
is essential to have the diagrams of changing the mechanical
properties during the heating. Therefore, we have used SL
5170 as pattern material. According to the datasheet of this
resin and Jacobs (1996), the Young’s modulus diagram has a
downward slope, and the thermal expansion has an upward
slop, while the temperature rises. The Poisson’s ratio for resin is
supposed to be 0.4 constant. The properties of investment
ceramic are constant during the temperature rise and are shown
in Table I. The modulus of rupture for this material is 30 MPa.
Figure 5 Analytical models, cylindrical model (right); quarter model
(left)
Sl pattern
Ceramic shell Symmetrical
planes
The numerical study has been performed in ANSYS
Workbench 11.0 software. For easing the analysis, an
isotherm temperature loading represents the heating
process, temperature is changed from 20 to 1008C with 58C
rise for each step. The SOLID187, SOLID186, CONTA174,
and TARGE170 elements are used for meshing the models.
Figure 6 shows the elements used for meshing models.
When an investment casting shell with a SL epoxy pattern
inside is in an autoclave or flash-furnace oven during the
burnout process, it is subjected to high temperature rise,
thermal expansion, and large strains. Since the difference of
the CTEs of epoxy and investment ceramic is more than one
order of magnitude, the epoxy pattern can exert considerable
stress on the ceramic shell. During the pattern burnout
process, the inner epoxy pattern expands more than the outer
ceramic shell. As a result, there exists contact pressure
between the ceramic shell and epoxy pattern. The inner epoxy
pattern is subjected to a compressive load, and the outer
ceramic shell is subjected to a tensile load (Yao and Leu,
2000). Referring to Figure 7, there will be a simple way to
obtain the magnitudes of hoop stress on the ceramic shell.
Assume that our SL pattern is a solid cylinder (rr), and this
model is coated with ceramic up to rc (Hague and Dickens,
2001). By using the Lame’s theories for an open-ended
thick-walled cylinder, the hoop stress in the ceramic, is
represented by:


r 2c þ r 2r
su maxðceramicÞ ¼ p ð1Þ
r 2c 2 r 2r
Figure 6 Body and contact meshing elements
-20 node
Structural
solid
(Solid 186)
-10 node
Tetrahedral
structural solid
(Solid 187)
-3D 8 node
Surface to
surface contact
(Conta 174) &
3d target Y
segment Z
(Target 170) X

Figure 7 A thick-walled cylinder representation of the pattern/shell

assembly

σ0 Where:
σr σ0 = Hoop stress
σr = Radial stress
Table I Investment casting material property P = Interface pressure
rr
between cylinder & core
Young’s modulus, Ec 5.09 GPa Resin rc = Outside radius of
CTE, ac 11.0 £ 102 7 mm/mm per 8C rc ceramic ‘Cylinder’
P
Poison ratio, vc 0.016 rr = Outside radius of resin
Source: Sandia National Laboratories (1995) Shell σ0 ‘Core’

257
 A novel lattice structure for SL investment casting patterns Rapid Prototyping Journal
Yousef Norouzi, Sadegh Rahmati and Yousef Hojjat Volume 15 · Number 4 · 2009 · 255 –263

su, the hoop stress is induced on the shell because of the
contact pressure in the interface of ceramic shell and SL
pattern, p the contact pressure represented by:
ar DT
p¼
ð1=E c ÞðK þ nc Þ þ ð1=E r Þð1 2 nr Þ
where ar is the CTE of SL 5170 resin, DT is the temperature
change (8C), Ec is the Young’s modulus of the ceramic shell,
Er is the Young’s modulus of the resin core, Vc is the Poisson’s
ratio of the ceramic shell, Vr is Poisson’s ratio of the SL 5170
resin, and K isðr 2c þ r 2r Þ=ðr 2c 2 r 2r Þ (Hague and Dickens, 2001).
Accordingly, contact pressure is the most useful result that
will help us to understand the structural performance of
models during burnout stage and it will lead us toward the
magnitudes of hoop stress. For deriving the accurate results
from FE analysis, several mesh sizes have been tested until
achieving the least differences in the data. Table II indicates
the results. There are three groups of results for contact
pressures. The original QuickCast 2.0 structure, new
octagonal structure with wall unit cells (cell that belongs to
QC 2.0), and octagonal structure with new bridge-like unit
cells are considered in this table.
For having a better comparison of results, the diagrams of
maximum hoop stress (derived from equation (1)) for three
models are shown in Figure 8. Referring to this figure; there
are 21 percent reduction in maximum hoop stress for model
#2, and 62 percent reduction for model #3, in comparison
with model #1 (which is representing the QuickCast 2.0).
The results of maximum hoop stresses are validating a good
agreement between the material properties and predicted style
of changing contact pressure during burnout process.
Practically, before the glassy region of SL 5170 resin, results
have an ascending behaviour and after reaching near 608C, it
turns to a descending manner. This also agrees with the idea
that most of the shell cracking takes place in the initial steps of
burnout stage or before the glass transition temperature of
thermosetting SL pattern (Yao and Leu, 1999). According to
the SL 5170 modulus of elasticity and thermal expansion
changing behaviour during temperature rise, the modulus of
elasticity for resin goes down with increasing the temperature
and CTE increases during heating process with a change in
slope near glassy region (60-908C). Therefore, small
increasing behaviour between 60 and 808C is explainable for
obtained results of maximum hoop stress. Although the
modulus of elasticity decreases with increasing the
temperature, resin continues its expansion and because of
the change of the slop in CTE diagram (near glass transition
temperature) the change in the descending style near 60-808C
for hoop stress diagrams is acceptable.
ð2Þ
Another satisfying result is about the deformation
behaviour of compared structures. As it is shown in
Figure 9(a) and (c), the octagonal lattice has an extra
rotational distortion as a whole torsion during the loading, in
comparison with the hexagonal structure. In addition,
according to Figure 9(b) and (d), the deformations of the
every single unit cell for octagonal structure is more
significant than the deformation of hexagons unit cells.
4. Void ratio
For performance of the SL patterns, void ratio (Rv) is an
important factor. Moreover, most of the time, it is a major
criteria for choosing better internal structure (i.e. better
structure has a bigger value of Rv). The bigger void ratio
means the lower mass inside the pattern. Therefore, the
amount of mass, which should be burned during burnout
process, will be decreased. Thereupon, this will cause a
reduction in time and cost of burnout process. Moreover,
reports from the foundries indicate that the foundry yield of
successful castings is a monotonically increasing function of
the void ratio (Jacobs, 1995). For obtaining the void ratios for
investigated structures, the measured mass of analytical
models are compared with the mass of a solid cylinder with
the same dimension (mass is measured by SolidWorks CAD
software). Through the definition of void ratio, a conceptual
equation is generated to obtain the magnitudes of Rv:
M solid 2 M quasi – hollow
Rv ¼ £ 100 ð3Þ
M solid
where Msolid is the mass of the solid model and Mquasi-hollow is
the mass of the semi-hollow model.
The magnitudes of void ratios for hexagonal and octagonal
patterns applying this equation are 90 and 95 percent,
respectively.
5. Drainage ability
Drainage characteristics of internal structure are another
influencing factor for having a successful burnout stage.

Table II Contact pressure, interface of epoxy pattern, and ceramic shell, results by ANSYS FE analysis
Model Mesh size Number of elements Max contact pressure ( 3 106, Pa)
1 – Quickcast 2.0 Hexagon 608 Coarse 29,596 5.6049
Medium 42,607 6.1049
Fine 56,140 6.5650
Fine þ Contact mesh resize 58,163 6.6764
2 – octagonal wall cell 608 Coarse 13,207 4.9610
Medium 40,607 4.8910
Fine 57,243 5.0210
Fine þ Contact mesh resize 23,088 5.3110
3 – octagonal bridge-like cell 608 Coarse 41,642 2.2240
Medium 56,426 2.6540
Fine 59,528 2.5320
Fine þ contact mesh resize 23,088 2.5680

258
 A novel lattice structure for SL investment casting patterns Rapid Prototyping Journal
Yousef Norouzi, Sadegh Rahmati and Yousef Hojjat Volume 15 · Number 4 · 2009 · 255 –263

Figure 8 Diagram of maximum hoop stress, belonging to selected The drainage ability of the novel octagonal structure is
models, results by ANSYS FE analysis compared with hexagonal structure in three concepts. First of
all, because of the geometry of the new structural unit cells (with
#1 #2 #3 smaller lateral areas), there will be smaller amount of contact
70 surfaces between cured and uncured in comparison with
QuickCast 2.0 structural unit cells. Moreover, this type of cells
Maximum hoop stress (Mpa)

60
provides open passes for liquid resin flow (Figure 10). In the
50 second place, the geometry of generated polygon is different in
hexagonal and octagonal structures. Therefore, the areas of
40 belonging enclosures are different. In fact, a successful drainage
30 would be obtainable with a more spacious enclosure. According
to Figure 11 for typical hexagon and octagon, the areas are:
20 

a cos 60 · a sin 60
10 Ahexagon ¼ 2 a2 þ 2
2
0 h p ffiffiffi i pffiffiffi
20 40 60 80 100 ¼ 2a2 1 þ ð1=2Þð 3=2Þ ¼ 2a2 ð1 þ 3=4Þ ¼ 2:9a2
Temperature (°C) n pffiffiffi o
AOctagonð60Þ ¼ 2a2 ð1 þ 3=4Þ þ ½aða þ 2a cos 60Þ

pffiffiffi pffiffiffi
In fact, a deficient drainage will produce thicker section areas ¼ {2a2 ð1 þ 3=4Þ þ 2a2 } ¼ 2a2 ½2 þ 3=4

in post-curing. Consequently, these thicker section areas will
exert higher magnitudes of stresses on ceramic shell, causing ¼ 4:9a2
ceramic shell failure. Drainage ability is affected by several  

2 acos45·asin45
factors including; resin viscosity, structural geometry of AOctagonð45Þ ¼ ½aðaþ2acos45Þ
þ2 a þ2
2
internal lattice, the thickness of the internal sections, and
the average amount of contact surfaces of cured and uncured pffiffiffi p ffiffiffi
¼ a2 þ 2a2 þ2a2 þ2a2 a2 ð5þ 2Þ ¼ 6:4a2
resin.

Figure 9 Deformation of hexagonal and octagonal structures, (a,c) total deformation; (b,d) deformation of unit cells

(b)
(a)
Rotational
distortion

(c) (d)

259
 A novel lattice structure for SL investment casting patterns
Yousef Norouzi, Sadegh Rahmati and Yousef Hojjat
Figure 10 Octagonal unit cells (right); QuickCast 2.0 (left)
Figure 11 Typical hexagon and octagon with equal side lengths
a a
60
45
–6
0
Generally, the magnitudes of areas indicate that the octagonal
enclosure has an opener area than a hexagonal with equal side
lengths. Moreover, it is approximately doubled for octagonal
one. Therefore, it is obvious that there will be better drainage
characteristics for octagonal structure because of reducing the
magnitude of cured and uncured resin contact surfaces.
Thirdly, the drainage of the epoxy resin is a laminar flow,
because the Reynolds number of the epoxy resin is in the range
of 10 £ 102 2 to 1 (Yao, 1998). The Hagen-Poiseuille equation
of laminar flow of a viscous fluid in a tube is:
pR4
Q¼ ð p1 2p2 Þ ð4Þ
8ml
where ( p1 2 p2) is the pressure drop, R is the radius, and m is the
viscosity of the fluid. The volumetric flow rate is proportional to
the fourth power of the radius of the tube, or is proportional to
the square of the area. Therefore, to improve resin drainage, it is
important to increase the cell size. Another problem of
incomplete drainage is the effect of liquid resin capillary and
viscous forces to form a natural meniscus at the corners of an
internal unit cell. The size of meniscus is related to the interior
angle. The larger open interior angle will generate a larger
meniscus shape. Consequently, the residual liquid resin will be
insignificant. From the standpoint of rheology, the internal
lattice must have a large open area and a large open interior
angle to achieve a successful drainage. A comparison is made for
hexagonal and octagonal structures with equal unit cell length
(a ¼ 6 mm) in Table III.
6. Dimensional accuracy
Since the early days of SL, resin shrinkage has been a major
cause of part inaccuracy. The initial shrinkage occurs when the
260
Rapid Prototyping Journal
Volume 15 · Number 4 · 2009 · 255 –263
Table III Comparison of the effect of internal angles of the hexagonal
and octagonal structures with equal unit cell length
Biggest interior angle Area (mm2) Void ratio (%)
Hexagonal 1208 104.4 90
Octagonal 1508 176.4 94.8
Octagonal 1358 230.4 95.1
liquid resin is polymerized to form a green part. There are other
forms of distortion caused by resin shrinkage. In QuickCast, the
shrinkage decreases due to reduction of internal mass and
amount of uncured resin between layers. Therefore, the
magnitude of internal mass can be a reliable factor for
comparing the dimensional accuracy of the SL patterns. For
qualitative comparison of dimensional accuracy of octagonal
and hexagonal structures, two cylindrical models are generated
in SolidWorks CAD package. Models are shown in Figure 12.
Internal dimensions are the same for both models.
Supposing the pattern’s material as SL 5170 with 1.14 g/
cm3 density, the magnitude of masses are 21.17 and 10.86 g
for hexagonal and octagonal patterns, respectively. The
magnitude of masses indicates a 49 percent reduction of
internal mass for octagonal model. Consequently, it is
concluded that the dimensional accuracy of a pattern with
octagonal structure will be better than the pattern with
hexagonal structure. Nevertheless, without a complete
experimental accuracy analysis, this deductive concluding
will not be rather reliable.
7. Experimental study
After the numerical analysis, the test samples are
geometrically designed with the SolidWorks package and
built using the SLA 5000 fabricator with WaterShede11120
resin (DSM Somos Co., 2005). The internally webbed SL
samples used in this study have a simple cylindrical geometry
of 60 mm (2.36 in.) diameter and 31 mm (1.22 in.) long. The
test samples are designed with two ends open for the insertion
of thermocouple wires and have a uniform heating of pattern
and ceramic shell. The built parts are then coated with
ceramic shells with the thickness of 4 mm.
For understanding the range of internal structural
dimensions, the thicknesses of structural unit cells built in
Figure 12 Octagonal and hexagonal structures used for accuracy
comparison
60
0
∅6
∅
 A novel lattice structure for SL investment casting patterns
Yousef Norouzi, Sadegh Rahmati and Yousef Hojjat
0.3 mm at first, then 0.6 mm. Final models that are used for
strain gauging analysis have 0.5 mm thickness of unit cells. For
first model (0.3 mm), the sweeper blade of SLA fabricator has
removed some parts of the internal web because they are so thin
and weak. On the other hand, second model has a strong
integrity and connection between internal webs. Figure 13
shows the primary models that are built with octagonal
structure and with different cell thicknesses. In addition,
Figure 14 shows the main models that is used for strain analysis.
Coating ceramic is zirconium slurry and models covered
with silica powder at each step of coating stage. Figure 15
shows the models after finishing the coating stage.
Figure 13 Primary octagonal models build with different cell
thicknesses
Cell thickness = 0.3 mm Cell thickness = 0.6 mm
Figure 14 Main octagonal and hexagonal models used for strain
metering, made by SLA 5000 and with Somos 11120
Cell thickness = 0.5 mm Cell thickness = 0.5 mm
Octagonal model Hexagonal model
Figure 15 Octagonal and hexagonal models after ceramic coating
261
Rapid Prototyping Journal
Volume 15 · Number 4 · 2009 · 255 –263
7.1 Strain gauge installation
The cylindrical geometry of ceramic shell makes it possible to
assume it as a thick cylinder. The difference between a thin
cylinder and a thick cylinder is that a thick cylinder has a
stress in the radial direction as well as a circumferential stress
and longitudinal stress. In addition, radial stress has only a
radial crippling effect on the wall of the ceramic shell and it is
not the main criteria for defining the failure of a thick
cylinder.
For octagonal and hexagonal models, strain gauges are
installed in longitudinal and circumferential directions.
Therefore, the magnitude of the strains in both directions is
the comparative criteria for two structures. Figure 16 is a
symbolic view of the strain gauges on SL pattern and ceramic
shell. Real locations of gauges are shown in Figure 17.
Besides, applying twisted thermocouple wires, simultaneous
magnitudes of temperature are obtained during heating
process (Figure 18). For heating the samples, a laboratorial
and small flash furnace has been used. Figure 19 shows the
rate of heating up for this furnace.
7.2 Results and discussion
One of the demerits of the hexagonal structure is its higher
stiffness in the perpendicular direction to the plane, in which
the structural levels are generated (or in Z direction).
According to Figure 20, the proposed octagonal structure
has an insignificant stiffness in Z direction in comparison with
conventional hexagonal structure.
Referring to Figure 21, a 56 percent reduction of maximum
strain has been observed for octagonal model in contrast with
hexagonal structure (Gauge #1).
Figure 16 Symbolic locations of installed strain gauges
4
1 3
SL pattern Ceramic shell
Figure 17 Locations of installed strain gauges
Axial
Second
circumferential First
circumferential
Internal
circumferential
 A novel lattice structure for SL investment casting patterns Rapid Prototyping Journal
Yousef Norouzi, Sadegh Rahmati and Yousef Hojjat Volume 15 · Number 4 · 2009 · 255 –263

Figure 18 Twisted thermocouple wires Figure 21 Comparison of internal circumferential strains

Gauge #1
Twisted thermocouple wires Hexagonal Octagonal
1,500
1,000
500

Micro strain
0
–500
–1,000
–1,500
–2,000
20 30 40 50 60 70 80
Temperature (°C)

Figure 22 Magnitudes of first external circumferential strain

Gauge #3
Hexagonal Octagonal
2,500

2,000

Micro strain
1,500
Figure 19 Heating rate of applied flash furnace
160 1,000

140 500
Temperature (°C)

120
100 0
20 30 40 50 60 70 80
80
Temperature (°C)
60
40 Figure 23 Magnitudes of second external circumferential strain
20 Gauge #4
0 Hexagonal Octagonal
0 300 600 900
2,500
Time (sec)
2,000
Figure 20 Comparison of longitudinal strains
Micro strain

1,500
Gauge #2
Hexagonal Octagonal 1,000
50
0 500
–50
Micro strain

–100 0
20 30 40 50 60 70 80
–150
–200 Temperature (°C)
–250
to collapse easier than hexagonal structure. According to
–300
–350 these results, maximum strain occurs near to the 608
20 30 40 50 60 70 80 C. According to Table IV, CTE for WaterShede11120 resin
Temperature (°C) has nearly doubled at 608C. Although, after 608C, the resin is
still continuing to expand, however, due to the fact that the
pattern has passed the glass transition temperature, therefore,
The results of two circumferential strain gauges, which are
installed on external face of ceramic shell (Gauges #3 and #4), Table IV Magnitudes of CTE of WaterShede11120 resin
indicate that there is a 47 and 44 percent reduction of maximum
hoop strains for octagonal structure in comparison with Temperature (8C) CTE ( 3 102 6, 1/8C)
hexagonal model. Figures 22 and 23 show these significant 240 to 0 66-67
enhancements. 0 to 50 90-96
All the diagrams of strain gauging indicate that octagonal 50 to 100 170-189
structure has a better performance than hexagonal structure 100 to 150 185-189
during burnout stage. That means octagonal structure intends

262
 A novel lattice structure for SL investment casting patterns Rapid Prototyping Journal
Yousef Norouzi, Sadegh Rahmati and Yousef Hojjat Volume 15 · Number 4 · 2009 · 255 –263

Table V Comparison of results for octagonal and hexagonal structures

Maximum hoop stress Gauge #1 Gauge #2 Gauge #3 Gauge #4
Structure (Pa) (maximum m strain) (maximum m strain) (maximum m strain) (maximum m strain)
Type of analysis Numerical Experimental Experimental Experimental Experimental
Hexagonal 5.766 £ 107 1257.1 2 79.4 2,230.2 1,962.635
Octagonal 2.190 £ 107 553 2 298.8 1248.352 1040.197
Comparison (percentage reduction) 62 56 73 44 47

it is weekend and not able to exert additional load to the References

ceramic shell. Having a similar changing behaviour for all
the magnitudes of strains (near 608C) indicates that the
experimental results are reliable and appropriate.
Additionally, because of using a dynamic data logger and
having a huge number of data points (approximately 1,400
data points for every gauge) to create smooth diagrams of
strains, error bars are not necessary to be defined for strain
gauging data.
8. Conclusion
A new internal lattice structure (offset octagonal) or a new SL
build style has been developed, which addresses some of the
problems of investment casting SL pattern. The octagonal
structure provides an internal arrangement for the SL pattern,
which allows it to collapse during the burnout stage much
earlier than the former hexagonal structure. Thus, avoids the
ceramic shell failure with higher ensuring factor than
hexagonal structure. A summary of the results is as follows:
.
The results of numerical study indicate that there is 62
percent reduction of maximum hoop stress of octagonal
pattern and ceramic shell interface, in comparison with
hexagonal pattern and ceramic shell interface.
.
For magnitudes of Rv, 5 percent improvement has been
achieved by new octagonal structure.
.
A qualitative analysis for drainage ability, regarding the
geometry of structural unit cells, the rheological
standpoint for resin flow, the overall geometry of the
enclosure, magnitudes of enclosure areas, and the average
amount of cured and uncured resin contact surfaces
indicates that octagonal pattern will have a better drainage
characteristics.
.
Reducing 49 percent of the internal mass of the octagonal
pattern in contrast with hexagonal pattern, probably will
lead to better dimensional accuracies somehow.
.
Table V illustrates a complete comparison of burnout
ability of models.
The obtained results indicate a significant improvement of
burning out the pattern with octagonal structure. That means
the magnitudes of exerted forces on ceramic shell will be
reduced applying this new structure. Hence, replacing the
hexagonal structure with octagonal one (and with novel
structural unit cells) will ensure using SL patterns as
sacrificial patterns in investment casting process more than
hexagonal structure (or QuickCast 2.0 build style).
3D Systems Co. (2002), Application Guide, Investment Casting
Using QuickCaste Build Style, Patterns produced using
3DSystems SLAw stereolithography systems, 3D Systems
Co., Rock Hill, SC.
DSM Somos Co. (2005), WaterShede11120 Resin Data Sheet,
DSM Somos Co., New Castle, DE.
Hague, R. and Dickens, P.M. (2001), “Improvements in
investment casting with stereolithography patterns”,
Proceedings of the Institution of Mechanical Engineers, p. 215
ProQuest Science Journals, Vol. 1.
Jacobs, P.F. (1995), “Rapid tooling”, World Class Design to
Manufacture, Vol. 2 No. 6, pp. 42-50.
Jacobs, P.F. (1996), Stereolithography and Other RP&M
Technologies: From Rapid Prototyping to Rapid Tooling,
ASME Press, New York, NY.
Sandia National Laboratories (1995), Properties of Investment
Ceramic, Internal Report, Sandia National Laboratories,
Albuquerque, NM.
Tromans, G. (2003), Developments in Rapid Casting,
Professional Engineering Publishing, London.
Yao, W.L. (1998), “Analytical and experimental study of
investment casting with laser stereolithography models”,
PhD dissertation, Department of mechanical Engineering,
New Jersey Institute of Technology, Newark, NJ.
Yao, W.L. and Leu, M.C. (1999), “Analysis of shell cracking
in investment casting with laser stereolithography patterns”,
Rapid Prototyping Journal, Vol. 5 No. 1, pp. 12-20.
Yao, W.L. and Leu, M.C. (2000), “Analysis and design of
internal web structure of laser stereolithography patterns for
investment casting”, Materials and Design, Vol. 21 No. 20,
pp. 101-9.
Further reading
Hague, R., D’Costa, G. and Dickens, P.M. (2001),
“Structural design and resin drainage characteristics of
QuickCast 2.0”, Rapid Prototyping Journal, Vol. 7 No. 2,
pp. 66-72.
Corresponding author
Sadegh Rahmati can be contacted at rahmati@rapidtoolpart.
com; srahmati2007@gmail.com

To purchase reprints of this article please e-mail: reprints@emeraldinsight.com

Or visit our web site for further details: www.emeraldinsight.com/reprints

263

View publication stats