3D Printed Patterns and Sand Casting
Moderator: Harold_V
3D Printed Patterns and Sand Casting
Thought I'd share a project I have been working on for the past few months, the future owner of the final part might be a member here on Chaski - not sure.
The original casting of this steam dome cover (goes on a British 7 1/4" gauge design called Paddington ) was found to be too small for the boiler as it was built. A larger casting is needed in order for the center bore to be the necessary diameter.
Using the original drawings and casting for reference I re-drew the part in 3D CAD and then scaled it up to the required size. Getting the compound curves right proved to be quite a challenge. Once I managed to get it correct I turned it into a split pattern and 3D printed it. I also 3D printed a core box to go along with it.
Ran out of metal on the first try, oops! However I managed to get a good pour the second time around!
The original casting of this steam dome cover (goes on a British 7 1/4" gauge design called Paddington ) was found to be too small for the boiler as it was built. A larger casting is needed in order for the center bore to be the necessary diameter.
Using the original drawings and casting for reference I re-drew the part in 3D CAD and then scaled it up to the required size. Getting the compound curves right proved to be quite a challenge. Once I managed to get it correct I turned it into a split pattern and 3D printed it. I also 3D printed a core box to go along with it.
Ran out of metal on the first try, oops! However I managed to get a good pour the second time around!
-Frank K.
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- Posts: 604
- Joined: Sun Feb 22, 2009 9:21 pm
- Location: massachusetts,usa
Re: 3D Printed Patterns and Sand Casting
So this is done for cope/drag greensand casting?
I have wondered about 3D printing for "lost wax/foam" type casts. Haven't had much to do with it.
Nice work though, piece looks good.
I have wondered about 3D printing for "lost wax/foam" type casts. Haven't had much to do with it.
Nice work though, piece looks good.
Re: 3D Printed Patterns and Sand Casting
Yes exactly, split pattern with core and petrobond sand, petrobond gives a very fine surface finish vs. greensand. (At least this is what I have been told.)
Yes you are correct 3D printers are also very suited for making lost wax patterns! Dick_Morris's build thread has a very cool example of this process here:
http://www.chaski.org/homemachinist/vie ... 9&start=24
-Frank K.
- Gary Armitstead
- Posts: 279
- Joined: Sat Mar 02, 2013 12:35 am
- Location: Burbank, CA
Re: 3D Printed Patterns and Sand Casting
I have been doing this for over two years now. I work with Marty Pinkston (FairWeather Foundry in Kent, Ohio). I design parts in MasterCam and Marty does the 3D printing for the pattern for the sand casting. It works great. So far only aluminum castings. But we are going to be doing other types of materials.
Gary Armitstead
Burbank, CA
Member LALS since 1980
Member Goleta Valley Railroad Club 1980-1993
Burbank, CA
Member LALS since 1980
Member Goleta Valley Railroad Club 1980-1993
Re: 3D Printed Patterns and Sand Casting
I was looking at building a DIY RepRap around 2014 but decided I already had too many hobbies and at that time complete ready-to-run printers were expensive.
I purchased my printer last year and wished I had bit the bullet a few years back, besides making patterns it is great for prototyping parts.
I purchased my printer last year and wished I had bit the bullet a few years back, besides making patterns it is great for prototyping parts.
-Frank K.
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- Posts: 1546
- Joined: Tue Mar 21, 2006 2:44 pm
- Location: East Hartford, CT
Re: 3D Printed Patterns and Sand Casting
Keep up the good looking work.
Rob
Rob
Re: 3D Printed Patterns and Sand Casting
I have passed off the casting to DMS where it is currently being machined:
-Frank K.
Re: 3D Printed Patterns and Sand Casting
Nice work Frank! Those cowls are goofy shaped at best! The ligan is looking healthier also!
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- Posts: 604
- Joined: Sun Feb 22, 2009 9:21 pm
- Location: massachusetts,usa