3D Printable Lost Foam Patterns With Foaming-Agent Filaments
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Solution Overview
Problem
Existing lost foam casting processes using conventional polystyrene patterns are time-consuming and require expensive tooling, while 3-D printing of wax-based patterns in investment casting takes at least 48 hours, limiting production efficiency and design freedom.
Innovation Solution
Utilizing 3-D printing with plastic filaments treated with foaming agents to create patterns, allowing for rapid production and reduced thermal energy requirements, with optimal filaments and agents identified for effective pattern creation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional polystyrene patterns are used in lost foam casting, then the casting process can be completed, but the production time is excessive and tooling costs are high
Solution Approach 1:
The patent changes the material parameters by using plastic filaments with foaming agents instead of conventional polystyrene, enabling the pattern to decompose at lower temperatures and reducing production time
Solution Approach 2:
The patent creates a composite material system combining plastic filaments (polypropylene, polyethylene, polystyrene, or their copolymers) with foaming agents (azodicarbonamide, sodium bicarbonate+citric acid, zinc stearate, calcium stearate, or 5-phenyltetrazole) to achieve both rapid production and effective foam decomposition
2Adaptability or versatility
If wax-based patterns are 3-D printed for investment casting, then design freedom is achieved, but production time exceeds 48 hours
Solution Approach 1:
The patent modifies the thermal parameters by incorporating foaming agents that decompose at lower temperatures, significantly reducing the time required for pattern decomposition and casting cycle time
Solution Approach 2:
The patent employs disposable plastic filament patterns with integrated foaming agents that rapidly decompose during casting, eliminating the need for expensive reusable tooling and reducing production time
3Use of energy by moving object
If conventional foam patterns are used, then casting can proceed, but thermal energy requirements are high
Solution Approach 1:
The patent changes the decomposition temperature parameter by using foaming agents that release gas at lower temperatures, reducing the thermal energy required for pattern decomposition and improving overall energy efficiency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables rapid production of lost foam casting patterns with high design freedom and improved thermal efficiency, achieving up to 0.1% dimensional accuracy and compatibility with conventional casting methods.
Implementation Method 1
The molten alloy decomposes the foam pattern with the vapors of decomposition being entrapped within the interstices of the sand
Implementation Method 2
The plastic filament may have a coating that resists decomposition by the molten alloy
Data Source
AI summary
A lost foam casting pattern that is constructed of a plastic filament, a foaming agent, and a coating. The lost foam casting pattern is printable on a 3-D printer. A 3-D printable material for the creation of a lost foam casting pattern is also disclosed where the material includes 95.0% to 99.75% by weight of a plastic filament combined with 0.25% to 5.00% by weight of a foaming agent. A method for preparing a lost foam casting pattern using the 3-D printable material is further described.