3D Printed Patterns and Sand Casting

Home enthusiasts discuss their Foundry & Casting work.

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FKreider
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Joined: Fri Feb 02, 2018 8:44 pm
Location: Massachusetts

3D Printed Patterns and Sand Casting

Post by FKreider »

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.
IMG_8371.JPG
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.
IMG_8425.JPG
IMG_8430.JPG
image2.jpeg
Ran out of metal on the first try, oops! However I managed to get a good pour the second time around! 8)
IDMK3951.JPG
FLMT57311.jpg
-Frank K.
steamingdon
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Location: massachusetts,usa

Re: 3D Printed Patterns and Sand Casting

Post by steamingdon »

Nice job Frank.
steamer
mihit
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Location: Tai Tokerau, NZ

Re: 3D Printed Patterns and Sand Casting

Post by mihit »

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.
FKreider
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Re: 3D Printed Patterns and Sand Casting

Post by FKreider »

steamingdon wrote: Sun Oct 06, 2019 6:52 pm Nice job Frank.
Thanks Don! :wink:
-Frank K.
FKreider
Posts: 338
Joined: Fri Feb 02, 2018 8:44 pm
Location: Massachusetts

Re: 3D Printed Patterns and Sand Casting

Post by FKreider »

mihit wrote: Mon Oct 07, 2019 12:54 am 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.
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.
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Gary Armitstead
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Re: 3D Printed Patterns and Sand Casting

Post by Gary Armitstead »

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
FKreider
Posts: 338
Joined: Fri Feb 02, 2018 8:44 pm
Location: Massachusetts

Re: 3D Printed Patterns and Sand Casting

Post by FKreider »

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.
-Frank K.
10 Wheeler Rob
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Re: 3D Printed Patterns and Sand Casting

Post by 10 Wheeler Rob »

Keep up the good looking work.

Rob
FKreider
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Re: 3D Printed Patterns and Sand Casting

Post by FKreider »

I have passed off the casting to DMS where it is currently being machined:
IMG_0046.jpg
-Frank K.
elm53
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Location: worcester,ma

Re: 3D Printed Patterns and Sand Casting

Post by elm53 »

Nice work Frank! Those cowls are goofy shaped at best! The ligan is looking healthier also!
FKreider
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Joined: Fri Feb 02, 2018 8:44 pm
Location: Massachusetts

Re: 3D Printed Patterns and Sand Casting

Post by FKreider »

elm53 wrote: Sat Nov 02, 2019 2:40 pm Nice work Frank! Those cowls are goofy shaped at best! The ligan is looking healthier also!
Thanks Larry!
-Frank K.
steamingdon
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Location: massachusetts,usa

Re: 3D Printed Patterns and Sand Casting

Post by steamingdon »

What is a ligan ? :shock: :? :? :? DMS
steamer
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