Continuous production process for 3D printed ceramic foundry filters, suiting all applications

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Metal components are required across many sectors including aerospace, automotive, manufacturing and construction. As such, cast metals in the UK generated sales of £1.89bn in 2017 (Cast Metals Foundation, Industry Census) with a global market of £123Bn in 2019 (Grandview Research, 2020). Liquid metal is cast into different and often specific shapes and it is important these components do not have defects which could lead to catastrophic failure. Filtration of the metal can reduce imperfections/defects which in turn minimises the number of failures that are unusable. Reducing the number of components manufactured to obtain high quality usable products consequently reduces the energy inputs and carbon dioxide emissions associated with this high energy consumption sector.Metal filters are often made from ceramic materials formed around polyurethane foam, however, when fired to remove the foam and create the filter pores, toxic fumes can be emitted and there is no guarantee of pore size and reproducibility. Additionally, shrinkage when materials are fired can be problematic adversely impacting the pore size.CAT International Ltd, a leading manufacturer of foundry filters and consumables, have developed a novel ceramic formulation (covered by a patent) and process that ensure high quality, reproducible filters for use in the metal casting foundry sector (foundation industry). We will develop an Additive Manufacturing (3D printing) process and proprietary ceramic formulation (ceramic materials combined with organic resin) that can be used to fabricate the filters. We have undertaken initial work and seek to carry our further industrial research to optimise our manufacturing process and formulation and test our materials in terms of properties and user needs.By using our new innovative process, we seek to enhance performance throughout the supply chain which will minimise materials wastage associated with defective parts. This will then minimise energy usage where the same inputs can create more usable parts as a result of better liquid metal pre-processing.Our project will improve the environmental performance of a sector that uses high volumes of raw material and increasing amounts of energy. Changes to the sector as a result of the Covid-19 pandemic provide us with a chance to build back a more environmentally sustainable industry in response to UK and global priorities to reduce waste and work towards net zero emissions by 2050\.