Segmented 3D Printed Shell Mold for Casting Complex Shapes
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Solution Overview
Problem
The existing precision casting techniques, such as dewaxing casting and 3D printing, face challenges including complex processes, contamination, low production efficiency, and high defect rates, especially when casting complex products, due to difficulties in removing residual powder from intricate mold structures and the need for whole shell mold rejection if defects occur.
Innovation Solution
The method involves splitting the shell mold into a runner part and pattern die parts, allowing for separate printing and assembly, enabling easier cleaning of residual powder and facilitating the creation of complex shapes, with the option to use ceramic or gypsum powder and laser sintering, and incorporating a sand box with steel balls and electromagnetic induction heating for improved casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If integrated 3D printing molding is used to print the whole shell mold at a time, then the manufacturing complexity is reduced, but it becomes difficult to remove residual powder from the pattern die cavity, resulting in defective casts
Solution Approach 1:
The patent divides the shell mold into separate components: a runner part and multiple pattern die parts. Each pattern die part can be printed and cleaned independently, allowing residual powder to be removed from each cavity before assembly. This segmentation resolves the contradiction by maintaining manufacturing simplicity while enabling thorough cleaning of each individual pattern die cavity.
2Productivity
If the whole shell mold is printed at a time, then production efficiency is improved, but any printing defect causes the entire mold to be rejected, resulting in high waste
Solution Approach 1:
By dividing the shell mold into a runner part and multiple separable pattern die parts, the patent enables independent printing and inspection of each component. If a defect occurs during printing, only the affected pattern die part needs to be rejected and reprinted, rather than the entire mold. This significantly reduces material waste while maintaining production efficiency.
Solution Approach 2:
The patent allows for selective discarding of only the defective pattern die part while recovering and reusing the other printed components. This approach minimizes material loss by salvaging the majority of the printed mold components that are not defective.
3Loss of time
If integrated molding is used, then the number of printing operations is reduced, but complex structures have higher probability of printing defects
Solution Approach 1:
The patent segments the shell mold into a runner part and multiple pattern die parts that can be printed separately. This reduces the complexity of each individual printing operation, thereby lowering the probability of printing defects for each component. The separate printing of simpler components increases overall printing success rate while the assembly process maintains production 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
This approach enhances the cleanliness and quality of the cast products, increases production efficiency, reduces waste, and allows for mass production of complex shapes by simplifying component structures and using standardized interfaces, while the steel balls and heating system improve mold durability and prevent defects during casting.
Implementation Method 1
incorporating a sand box with steel balls and electromagnetic induction heating for improved casting
Data Source
AI summary
A casting method using combined 3D printed shell mold and the combined shell mold used in the method. The method consists of shell mold making and casting steps. The shell mold is constructed by combination. First, the 3D printer at least prints out a runner part and several pattern die parts for molding products. In the print run, the first interfaces corresponding to the quantity of pattern die parts are printed out integrally on the runner part. The second interfaces corresponding to the first interfaces are formed on the pattern die parts. Afterwards, the first interfaces and the second interfaces are butted, the primary runner in runner part is connected to the die cavities in pattern die parts, the runner part and pattern die parts are combined to form a shell mold for casting multiple products at a time.