Rapid Freeze Prototyping and Investment Casting Application

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This project is aimed at demonstrating the feasibility of investment casting with ice patterns generated by Rapid Freeze Prototyping, a novel solid freeform fabrication process which builds a three-dimensional part according to a CAD model by depositing and freezing water droplets layer by layer. The feasibility study includes: exploring ways of handling and transporting ice patterns between stations for the subsequent investing casting process; identifying suitable materials including powders and binders for making ceramic shells from ice patterns; studying limitations on feature shapes and sizes of ice patterns for investment casting and ability to retain sharp features of ice patterns over time; and investigating the dimensional accuracy and surface finish of the metal castings obtained from ice patterns. If the project is successful, it will likely create a significant new approach for rapid prototyping and small-quantity manufacturing of investment casting parts with ice patterns fabricated by a cost-effective and environmentally benign method. This could significantly improve the environmental impact of processing molds in the investment casting industry.