Ceramic 3D Printing and Metal Casting Combine to Make Complex Parts

Additive Manufacturing Media

31 Aug 202201:56

Summary

TLDRتتضمن التكنولوجيا ال3D الطباعة ال拂طاسية لإنتاج أجزاء معدنية معقدة بشكل فعال وتكلفة مقارنة بتقنيات التصنيع التقليدية. في مقال مصور في أрисتو كاست في ألمونت، ميشيغان، يستخدم 3D الطباعة ال拂طاسية لإنشاء قواعد 3D مطبوعة على أقمشة ال拂طاسة، مما يتيح لإنشاء أجزاء معقدة وداخلية بتكلفة أقل. يتضمن العملية التنظيف والتنظيف الشهي والتصنيع النهائي للأجزاء ال拂طاسية، مما يساعد في تقليل التكاليف ويضمن جودة الإنتاج.

Takeaways

🌐 التصنيع ال月加入 لتصنيع العناصر الメتال ال月加入 يتيح تحقيق الأشكال الداخلية المعقدة للأجزاء.
🔍 يمكن للتقنيات القائمة على ال3D الطباعة أن تتجاوز قدراتها المتوقعة في الإنتاج.
🏭 يتم التصوير في مورunfold مfacturing في ألمونت، ميشيغان.
💡 يتم التجربة في استخدام الطباعة ال3D لمساعدة في التصنيع بالنحيفة.
📈 يستخدم عملية P.I.C.S. (الغشاء الصناعي ال打好) لطباعة القشرة ال керамиكية.
🔄 يتيح التصميمات ال3D الطباعة المصنوعة من الألياف ال доступة على نطاق واسع لتكوين الأجزاء.
💰 يمكن أن يؤدي هذا إلى إنتاج الأجزاء الメتال الカラهية بتكلفة أقل.
🧼 يتم تفريغ القشرة ال3D الطباعة الكراميكية من خلال عملية التنظيف.
🛁 يتم غسل القشرة بعد الطباعة بالألكوهول المشتعل.
🔥 تتم تسخين القشرة الكيراسية بعد التنظيف والتنظيف.
🌀 يتم تجميع القشرة الكيراسية مع الشراشير لتحضيرها للفرس.

Q & A

What is the main advantage of metal additive manufacturing in terms of part geometries?
-Metal additive manufacturing is capable of achieving complex internal part geometries that no other process can achieve.
What is the P.I.C.S. process used by Aristo Cast?
-The P.I.C.S. (Printed Investment Casting Shell) process is a method that uses 3D printed ceramic shells to create intricate, curving internal geometries of components made from widely available alloys used in casting.
How does the P.I.C.S. process potentially reduce costs compared to traditional metal additive manufacturing?
-The P.I.C.S. process can potentially result in an intricate metal part at a lower cost than is often possible with traditional metal additive manufacturing processes, by utilizing more accessible and cost-effective materials and methods.
What is the role of 3D printed ceramic shells in the P.I.C.S. process?
-The 3D printed ceramic shells are used to create the complex internal geometries of the components. They are later leached out to remove them from the part.
What are the steps involved in the P.I.C.S. process after 3D printing the ceramic shells?
-After 3D printing, the ceramic shells are cleaned with isopropyl alcohol, soaked in a tank for loose slurry removal, and then sintered.
How are the ceramic shells attached for the P.I.C.S. process?
-The ceramic shells are attached to a sprew, which is a type of handle or support structure used in casting.
What is the purpose of dipping the sprew and shell assembly into ceramic slurry?
-Dipping the assembly into ceramic slurry helps to create additional layers around the 3D printed ceramic shells, building up the investment casting shell.
How long does it typically take to complete a build of P.I.C.S. shells?
-A build of P.I.C.S. shells can take about 10 hours.
What is the primary material used in the 3D printing step of the P.I.C.S. process?
-The primary material used in the 3D printing step is ceramic, which is also used in the subsequent slurry coating step.
How does the P.I.C.S. process contribute to the overall goal of manufacturing complex metal parts?
-The P.I.C.S. process contributes to manufacturing complex metal parts by enabling the creation of intricate internal geometries that are not feasible with conventional casting methods, while potentially reducing costs and material waste.

Outlines

00:00

💡 Innovations in Metal Additive Manufacturing

This paragraph discusses the capabilities of metal additive manufacturing, particularly in achieving complex internal part geometries that traditional processes cannot replicate. It introduces the concept that some existing processes, like 3D printing, may be more versatile than previously thought. The narrative takes us to Aristo Cast in Almont, Michigan, where they are experimenting with an aid to investment casting using 3D printing of ceramic through their P.I.C.S. (Printed Investment Casting Shell) process. This process allows for the creation of intricate, curving internal geometries of components made from widely available alloys used in casting, potentially leading to the production of complex metal parts at a lower cost than other additive manufacturing processes in metal. The paragraph also outlines the steps involved in the P.I.C.S. process, including the 3D printing, cleaning, sintering, and assembly of the ceramic shells, and the final preparation for the pour.

Mindmap

Keywords

💡Metal additive manufacturing

Metal additive manufacturing is a process of 3D printing using metal materials to create complex and detailed parts. It is known for its ability to produce internal geometries that traditional manufacturing processes cannot achieve. In the context of the video, this technology is being compared with an innovative method that combines 3D printing with investment casting, potentially offering cost and design advantages.

💡3D printing

3D printing is a manufacturing process where an object is created by laying down successive layers of material. In the video, 3D printing is used to create ceramic shells, which are then used in the investment casting process for metals. It is a key technology that enables the creation of intricate designs and shapes that were previously unattainable.

💡Investment casting

Investment casting is a manufacturing process where a part is created by melting a metal and pouring it into a mold, which has been made by a pattern around which a ceramic shell is built. This process allows for the creation of complex shapes with high precision. In the video, investment casting is being enhanced with the use of 3D printed ceramic shells, which can create more intricate designs at a potentially lower cost.

💡Ceramic shells

Ceramic shells are the outer layers created through 3D printing that form the mold for investment casting. These shells have intricate internal geometries that define the shape of the final metal part. They are crucial in the P.I.C.S. process as they allow for the creation of complex metal parts with high precision and detail.

💡P.I.C.S. process

The P.I.C.S. process, or Printed Investment Casting Shell, is a method that combines 3D printing and investment casting. It involves using 3D printed ceramic shells to create molds for casting metal parts. This process is highlighted in the video as a way to achieve intricate metal parts at a lower cost than traditional additive manufacturing processes.

💡Alloys

Alloys are mixtures of metals that are widely used in casting due to their desirable properties, such as strength and resistance to corrosion. In the context of the video, the use of accessible and widely available alloys is emphasized as they can be shaped into intricate designs using the P.I.C.S. process.

💡Cost-effectiveness

Cost-effectiveness refers to achieving the desired outcome at the lowest possible cost. In the video, the P.I.C.S. process is presented as a potentially more cost-effective method for creating intricate metal parts compared to traditional additive manufacturing processes. This is due to the use of widely available alloys and the innovative combination of 3D printing and investment casting.

💡Leaching

Leaching is the process of removing a substance from a mixture by dissolving it in a solvent. In the context of the video, the 3D printed ceramic shells are leached out to remove them from the metal part after the casting process. This step is crucial for obtaining the final metal component with the desired intricate design.

💡Sintering

Sintering is a thermal process that increases the density of a material by heating it to a temperature below its melting point. In the video, the ceramic shells undergo sintering after 3D printing to strengthen and solidify their structure before being used in the investment casting process.

💡Sprew

A sprew is a type of gating system used in investment casting to control the flow of molten metal into the mold. It is attached to the ceramic shell and ensures that the metal is poured into all parts of the mold accurately. In the video, the sprew is used in conjunction with the P.I.C.S. process to facilitate the casting of the intricate metal parts.

💡Pouring

Pouring is the act of transferring molten metal into the mold in the investment casting process. After the ceramic shell has been prepared and attached to a sprew, and the slurry has been applied, the molten metal is poured into the mold to create the final part. This step is critical in determining the quality and accuracy of the finished metal component.

Highlights

Metal additive manufacturing can achieve complex, internal part geometries that other processes cannot.

Some existing processes might be more capable than previously thought, thanks to advancements in 3D printing.

The metal part discussed was not 3D printed but was made through investment casting.

Aristo Cast in Almont, Michigan, is experimenting with an aid to investment casting using 3D printing.

The P.I.C.S. process, or Printed Investment Casting Shell, utilizes 3D printed ceramic shells for intricate component designs.

Ceramic shells 3D printed on Admatec's system allow for complex, curving internal geometries of components.

These components can be made from widely available alloys commonly used in casting.

The result of this process could be intricate metal parts at a lower cost than traditional additive manufacturing processes.

The 3D printed ceramic shell is leached out to be removed, as part of the process.

The P.I.C.S. shells' build took approximately 10 hours to complete.

After 3D printing, the shells are cleaned with isopropyl alcohol.

The shells are soaked in a tank for an extended period for loose slurry removal.

Sintering is a subsequent step in the process after cleaning and soaking.

The ceramic shells are attached to a sprew for further processing.

The sprew with the shell assembly is dipped into a ceramic slurry made from the same ceramic used in 3D printing.

The slurry-coated assembly dries before it's ready for the pour.