Multi-phase 3D printing of wax-based systems for large-scale casting pattern and mold development

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Casting is a fundamental manufacturing process employed in the production of metal parts. Cast parts are widely used in many industries in Alberta. A fundamental step in the casting process is the production of a pattern followed by construction of the mold which is conventionally undertaken through either machining or more recently, through the use of the 3D printing, vat photopolymerization process. This process is highly energy-intensive and slow with significant negative emissions. It is also limited in scale and is unable to produce large parts. This project proposes research and development of a scalable and environmentally friendly process for large parts through multi-phase, multi-material simultaneous pattern and mold 3D printing process. The project will investigate the fundamental questions related to the manufacturing process, material development, the physics of liquid and slurry solidification, and the use of real time image/scanning based methodology to provide process feedback and control related to an integrated manufacturing system capable of producing precision castings. The development of this process will invigorate the Alberta economy leading to job creation in advanced manufacturing through the availability of a safer, efficient, and high quality manufacturing technology for metal parts which currently are not available in Alberta.