Aluminum casting using 3D printed master models

The goal of the project was to provide the customer with a solution for replacing damaged parts. The aim was to optimize the current design, propose an equivalent material, and thereby extend the lifespan and reliability of their motorcycles while reducing the cost of the replacement part.

Through reverse engineering and 3D printing, we created a molding model for gravity casting using a sand mold mixture.

• Material selection: PLA was chosen for additive manufacturing due to its availability, low cost, and sufficient strength for this application.
• 3D printing technology: The FDM (Fused Deposition Modeling) technology was selected for its affordability and production speed.
• Design process: The process began with digitizing the required spare part, then the model was technologically optimized for gravity casting and 3D printing. The design went through several iterations to achieve maximum accuracy and quality, while improving the mechanical properties compared to the original part.

Steps:

1. 3D scanning: Capturing the external surfaces of the part to create its digital copy. CT-3D scanning technology was used to achieve higher accuracy and to detect potential internal defects in the part.
2. 3D design: Creating a parametric solid model based on the 3D scan output.
3. Technological adjustment: Designing suitable technological modifications for gravity casting technology in cooperation with the foundry. Appropriate machining allowances were proposed for subsequent conventional machining.
4. Prototyping: Printing the prototype in white PLA using FDM technology, followed by production by casting from aluminum alloy.
5. Testing: Verifying the dimensional accuracy and functionality of the prototype, as well as testing the machining process.
6. Technological adjustment: Further modification of the 3D design based on feedback from production and sample testing.
7. Series production: Production of molding models using FDM technology and subsequent series production by gravity casting of aluminum alloy in tens of pieces with additional machining.