Advanced Procedures for Series Production with 3D-Printed Core Packages

The application of additive-manufactured cores and molds is of great interest for complex cast components. Nevertheless, several challenges still exist in utilizing binder jetting in the multi-step additive manufacturing process for foundry applications to its fullest extent. This contribution shows methods that facilitate the use of 3D-printed sand molds and cores in casting series applications. The binder jetting process itself is assessed from an overall process chain perspective to highlight the benefits of its application in series production. The challenges associated with automating mold cleaning for highly complex casting contours are depicted. In particular, employing the method of cleanable mold partitioning is shown to enhance the automation level of the overall process. Mold design tailored to 3D printing is demonstrated to contribute to overall cost and time savings in enhanced core packages. Topology-optimized, lightweight part designs involving complex freeform surfaces may require mold partitioning associated with laborious burr removal processes. A new approach in answer to the shortage of skilled workers in the harsh and hazardous foundry environment is shown. Implementing motion tracking technology is demonstrated to enable economical automated burr removal for minor quantities or high variant diversity in the future foundry. All the methods shown are of great importance for introducing printed core packages into series production.