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A Hybrid Rapid Pattern Manufacturing System for Sand Castings
2009 Proceedings of the Solid Freeform Fabrication Symposium
  • Matthew C. Frank, Iowa State University
  • Frank Peters, Iowa State University
  • Xiaoming Luo, Iowa State University
  • Fangqi Meng, Iowa State University
  • Joseph Edward Petrzelka, Iowa State University
Document Type
Conference Proceeding
Publication Version
Published Version
Publication Date
Conference Title
2009 Solid Freeform Fabrication Symposium
Conference Date
August 3-5, 2009
(30.267153, -97.74306079999997)
This paper presents a Rapid Pattern Manufacturing system developed for the sand casting process. It involves both additive and subtractive techniques whereby slabs are sequentially bonded and milled using layered toolpaths. As such, patterns are grown in a bottom-up fashion, both eliminating the need for multi-axis operations and allowing small features in deep cavities. Similar approaches exist in the literature; however, this system is specifically targeted at large wood and urethane sand casting patterns. This method introduces a novel support structure approach by integrating a flask into the pattern build process. We also present adaptive slicing algorithms that optimally place layer transitions to avoid thin sections near flats, peaks, and valleys or where interaction with chemically bonded sand could be problematic. The system has been implemented in an automated machine capable of producing patterns in excess of several thousand pounds. Preliminary testing of the system in the development of next generation military equipment is presented in a case study.

This is a proceeding from the Solid Freeform Fabrication Symposium (2009): 35. Posted with permission.

Copyright Owner
Laboratory for Freeform Fabrication
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Citation Information
Matthew C. Frank, Frank Peters, Xiaoming Luo, Fangqi Meng, et al.. "A Hybrid Rapid Pattern Manufacturing System for Sand Castings" Austin, TX2009 Proceedings of the Solid Freeform Fabrication Symposium (2009) p. 35 - 46
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