Development, evaluation, and selection of rapid tooling process chains for sand casting of functional prototypes

Abstract

This paper discusses the results obtained from studies on different rapid tooling process chains for improved design and manufacture of foundry equipment for sand casting of prototypes in final material for functional and pre-production tests of vehicles, using the three-dimensional printing process as core technology. Subsequently, while considering aspects such as time, cost, quality (accuracy and surface roughness), and tool life, a framework for evaluation and selection of the most suitable process chain in accordance to specific requirements is presented. Apart from only using these process chains for prototype manufacturing, initial results from a study to apply one of these process chains in automated sand casting full production is also presented. This research builds on an in-depth characterization of the accuracy and repeatability of a three-dimensional printing process.