Design & Optimization for 3D Sand Printing

Learning Outcomes

  • Describe the various additive manufacturing techniques used in metalcasting.
  • Describe the 3D sand printing process.
  • List the process considerations for casting quality.
  • Describe cost implications of the process and their advantages/disadvantages.
  • Identify the optimal type of parts for the process.
  • List the design considerations for casting quality.
  • Identify methods to improve designs.
  • Describe the role of casting process simulation.

Course Introduction

There are many advantages to the use of 3D sand printing of molds and cores, especially when it comes to casting design and the technology is being rapidly adopted in all sectors. The course focuses on designing castings for the 3D sand printing process, as well as optimizing existing designs to take advantage of the unique capabilities afforded. Topics include the advantages, limitations and when to the process. Important considerations such as communication, storage and handling of cores and molds, gating design and the use of simulation, file formats, and key features allowable. Case studies will be used throughout the course.

Benefits to Taking the Course

Attendees will walk away with concrete ideas for cost reduction of core assemblies via core integration, reduction of lead times and prototyping costs, potentially eliminating costs for pattern and tooling storage and maintenance, and assessing the break-even point between the technology and part volume. Participants will be able to talk intellectually, cut through the hype about the subject and be the expert in their organization on 3DSP technology applications to get castings made faster, more accurately, and with less scrap.

Module 1: Introduction

Module 2: 3D Sand Printing

  • 3DSP Compared to Traditional Methods
  • Cost and Time Implications
  • Considerations and Limitations

Module 3: 3D Sand Printing Process

  • How 3D Sand Printing Works
  • Printers
  • Materials
  • Part Handling

Module 4: Casting with 3DSP Molds and Cores

  • Mold and Core Types
  • Mold Assembly
  • Casting

Module 5: Designing for 3DSP

  • Design Process
  • Design as a Tool
  • Print Orientation
  • Casting Process Modeling

Module 6: Optimization

  • Improving Part Designs
  • Communication
  • Quality and Defects

Conclusion

 

What our students are saying.....

"A great course and instructors were an amazing help."
"Very good class and detailed. Lots of good examples."
"Overall a well-thought out course with great experts."
"Excellent course that provided great details on this technology."