fdm for sand casting
Post on 01-Oct-2015
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CASE STUDY: Taking the bite out of sandcasting CLIENT: Jason Christopher PROJECT: Crocodile Sculpture
FDM for Sand Casting An Objective3D Case Study
The team at Objective3D produced these parts flawlessly
using their Fortus Production systems. The FDM printing
process saved me hours of meticulous modelling work and
the parts themselves proved durable enough to withstand
the rigours of the foundry, as well as providing a great finish
for the mould surface. Jason Christopher www.jasonchristopherartist.com
The Aim: To produce a FDM pattern to be used for sandcasting a
complex metal sculpture (model) which will be bronze electroplated as
the piece de resistance in an art exhibition.
The 3D Printing requirements: As the Fused Deposition Modelling
(FDM) model was to be used as a mould for sand-casting, the parts had
to be strong enough to withstand the pressure of the moulding process,
able to be sanded to a high surface finish and cost effective to reduce
the overall expense of the project.
Jason Christopher designed the sculpture for manufacture - this ensured
the design could be split in half and cast effectively. With this in mind,
the same process was applied to the 3D Printed model. The team at
Objective3D Parts sectioned the build file to allow sections to be built
simultaneously across six in-house Fortus FDM 400 production systems.
This substantially reduce production time and costs, reducing the
estimated build time from 400 hours to only 180 hours. This also
drastically reduced material costs as no support material was required
due to the clever work of Objective3Ds engineers. The pattern was also
built with a T20 tip in sparse filled and ABS-M30 which lead to additional
time and cost savings.
After the 3D Printing: The 3D Printed model was meticulously
prepared for shipping and sent to the Client who assembled the parts,
filled and sanded the joins and applied several coats of primer and paint
filler to the entire model for a smooth surface finish. From here, the
pattern is complete and ready for casting.
At the foundry, the pattern is used to create a negative impression in
compacted sand. This is then carefully prepared for the pour by cutting
in runners and rises to allow for draw (metal shrinkage). The mould is
then closed ready for the metal pour.
The metal is left to cool in the mould before the sand is excavated
leaving the raw cast behind. The runners and rises are removed
manually, before the two casts are machined to allow for tapping screws
which will hold the two sides together. Once assembled, the cast is
cleaned of any leftover sand, grease and oil before being electroplated
in bronze, giving its final dramatic appearance.
OBJECTIVE3D, 33-35 YAZAKI WAY, CARRUM DOWNS, VIC AUSTRALIA 3201 www.objective3d.com.au
3D Printed Benefits:
The FDM pattern is reusable
ABS-M30 is stable over time
Production time was halved
Artists time can be spent
creating additional works and
not modelling just one
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