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

Additive Manufacturing Media

31 Aug 202201:56

Summary

TLDRAristo Cast in Almont, Michigan is innovating investment casting with the integration of 3D printing technology. Their P.I.C.S. process utilizes 3D printed ceramic shells to create intricate metal parts with complex internal geometries. This method allows for the production of detailed components from widely available alloys at potentially lower costs compared to traditional additive manufacturing. The process involves cleaning, sintering, and dipping the shells into ceramic slurry before pouring, offering a promising blend of modern and classic manufacturing techniques.

Takeaways

🌐 Metal additive manufacturing enables the creation of complex internal part geometries that are unattainable with traditional methods.
🔍 Existing processes like investment casting may be more capable than previously thought when combined with 3D printing technology.
🏭 The video is set at Aristo Cast in Almont, Michigan, where they are exploring the use of 3D printing to aid in investment casting.
📈 Aristo Cast utilizes a P.I.C.S. (Printed Investment Casting Shell) process to enhance their casting capabilities.
🔄 The P.I.C.S. process involves 3D printing ceramic shells, which allows for intricate and curving internal geometries in the components.
💡 Components made with this process can be created from widely available alloys, potentially reducing costs compared to other metal additive manufacturing processes.
🧼 After 3D printing, the ceramic shells undergo a cleaning process with isopropyl alcohol and a soak to remove loose slurry.
🔥 The shells are then sintered, a heat treatment process that increases the strength and durability of the ceramic material.
🔄 The ceramic shells are attached to a sprew, a tree-like structure that organizes multiple parts for the casting process.
🌊 The sprew assembly is dipped into a ceramic slurry, which is the same material used in the 3D printing of the shells, to prepare it for the pour.
⏱️ The entire build of P.I.C.S. shells takes approximately 10 hours, highlighting the efficiency of the process.

Q & A

What is metal additive manufacturing capable of achieving?
-Metal additive manufacturing is capable of achieving complex, internal part geometries that no other process can achieve.
How does the 3D printing process mentioned in the script differ from traditional methods?
-The 3D printing process mentioned in the script aids investment casting by using ceramic shells, allowing for intricate and curving internal geometries of components.
Where is the location of Aristo Cast?
-Aristo Cast is located in Almont, Michigan.
What is the P.I.C.S. process?
-P.I.C.S. stands for Printed Investment Casting Shell, a process that involves 3D printing ceramic shells for use in investment casting.
What material is used for 3D printing in the P.I.C.S. process?
-Ceramic is the material used for 3D printing in the P.I.C.S. process.
What is the significance of the Admatec system mentioned in the script?
-The Admatec system is the 3D printing setup used to create the ceramic shells for the P.I.C.S. process.
What alloys are used in the P.I.C.S. process?
-The alloys used in the P.I.C.S. process are widely available alloys commonly used in casting.
How does the P.I.C.S. process potentially reduce costs?
-The P.I.C.S. process can potentially result in an intricate metal part at a lower cost than is often possible with traditional additive manufacturing processes in metal.
What happens to the 3D printed ceramic shell during the process?
-The 3D printed ceramic shell is leached out to be removed.
How long does it take to build P.I.C.S. shells?
-It takes about 10 hours to build P.I.C.S. shells.
What are the steps taken after 3D printing the shells in the P.I.C.S. process?
-After 3D printing, the shells are cleaned with isopropyl alcohol, soaked for loose slurry removal, and then sintered.
How is the final assembly prepared for the pour in the P.I.C.S. process?
-The ceramic shells are attached to a sprew, and that assembly on the sprew is then dipped into a ceramic slurry to prepare it for the pour.

Outlines

00:00

🏭 Innovations in Metal Additive Manufacturing

This paragraph discusses the capabilities of metal additive manufacturing, particularly in achieving complex internal part geometries. It highlights the potential of existing processes, such as investment casting, to be enhanced by 3D printing technology. The narrative takes us to Aristo Cast in Almont, Michigan, where experiments are being conducted on an aid to investment casting using 3D printed ceramic shells. The P.I.C.S. (Printed Investment Casting Shell) process allows for intricate and curving internal geometries of components made from widely available alloys used in casting. The result is the possibility of producing complex metal parts at a lower cost compared to traditional additive manufacturing processes. The process involves 3D printing ceramic shells, which are then leached out, cleaned with isopropyl alcohol, soaked for loose slurry removal, and sintered. The shells are attached to a sprew, dipped into a ceramic slurry, dried, and finally prepared for the pour.

Mindmap

Keywords

💡Metal additive manufacturing

Metal additive manufacturing refers to a process of creating 3D metal objects by layering materials together, often using a 3D printer. This technology is known for its ability to produce complex geometries that traditional manufacturing methods cannot achieve. In the video, it is mentioned as a comparison to the P.I.C.S. process, highlighting the unique capabilities of combining 3D printing with investment casting.

💡3D printing

3D printing is a manufacturing process where an object is created by laying down successive layers of material until a desired object is produced. The technology has various applications across industries and is particularly noted for its ability to create intricate and complex designs. In the context of the video, 3D printing is used to create ceramic shells for investment casting, which allows for the production of metal parts with complex internal geometries.

💡Investment casting

Investment casting is a manufacturing process often used to create precision castings, typically of intricate shapes and designs. It involves creating a wax model of the desired part, covering it with a ceramic material to form a mold, and then melting and pouring molten metal into the mold. The video highlights a company, Aristo Cast, that is experimenting with a novel approach to investment casting by using 3D printed ceramic shells.

💡Aristo Cast

Aristo Cast is a company based in Almont, Michigan, that specializes in casting services. In the video, it is noted for its experimentation with an innovative method that combines 3D printing and investment casting. This company is at the forefront of exploring how these technologies can be integrated to produce complex metal parts more cost-effectively.

💡P.I.C.S. process

The P.I.C.S. process, or Printed Investment Casting Shell, is a method that utilizes 3D printing technology to create ceramic shells for investment casting. This process allows for the production of parts with intricate internal geometries that are not possible with traditional casting methods. The P.I.C.S. process is highlighted in the video as a way to potentially reduce costs and increase the complexity of metal parts produced.

💡Ceramic shells

Ceramic shells are the 3D printed structures made from ceramic material that are used in the P.I.C.S. process. These shells form the mold for investment casting, and their intricate designs are only possible due to the precision of 3D printing technology. The ceramic shells are later leached out to remove them from the metal part.

💡Accessible widely available alloys

Accessible widely available alloys refer to metal materials that are commonly used in casting and can be easily obtained. These alloys are known for their properties suitable for casting and are the basis for creating a variety of metal parts. The video suggests that the P.I.C.S. process can be used with these familiar alloys, making the technology more accessible and practical for the铸造 industry.

💡Lower cost

Lower cost in the context of the video refers to the potential reduction in expenses associated with producing complex metal parts. By using the P.I.C.S. process, which combines 3D printing and investment casting, the manufacturing process may become more efficient and less expensive than traditional additive manufacturing processes.

💡Leaching

Leaching is the process of removing a substance from a material by dissolving it in a solvent or through a chemical reaction. In the context of the video, leaching refers to the removal of the 3D printed ceramic shells from the metal part after the casting process. This is a crucial step to ensure that the ceramic material does not remain within the final metal product.

💡Sintering

Sintering is a heat treatment process that increases the density of a material by fusing particles together without melting the entire object. In the P.I.C.S. process, sintering is used to strengthen the 3D printed ceramic shells, making them suitable for use in the investment casting process. This process is essential for ensuring the structural integrity of the ceramic shells before they are used to cast metal parts.

💡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 an essential component that ensures the metal is distributed evenly throughout the ceramic shell, filling the intricate details of the part being cast. In the video, the sprew is mentioned as the attachment point for the ceramic shells before they are dipped into the ceramic slurry.

💡Pour

The pour is the final step in the casting process where molten metal is introduced into the mold. After the ceramic shell has been prepared through 3D printing, sintering, and attachment to a sprew, the pour is when the actual metal part is formed. This step is critical for the creation of the final product, as it determines the quality and accuracy of the metal part.

Highlights

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

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, is a method that utilizes 3D printed ceramic shells.

The 3D printed ceramic shells allow for intricate, curving internal geometries of components.

These components can be made from widely available alloys 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, which is a crucial step in the process.

The P.I.C.S. shells' build took approximately 10 hours, showcasing the efficiency of this method.

After 3D printing, the shells are cleaned with isopropyl alcohol, emphasizing the importance of post-processing.

Loose slurry removal involves soaking the shells in a tank for an extended period.

Sintering is the next step after cleaning, which consolidates the ceramic material.

The ceramic shells are attached to a sprew, which is a necessary step for the assembly process.

The assembly on the sprew is dipped into a ceramic slurry, which is the same material used in 3D printing.

Once the slurry dries, the component is ready for the pour, indicating the final preparation stage.

This process combines the strengths of 3D printing and traditional casting to create more cost-effective and complex metal parts.