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

铸造是生产金属零件的一种基本制造工艺。铸件广泛应用于阿尔伯塔省的许多行业。铸造过程中的一个基本步骤是生产一个图案，然后是模具的构造，这通常是通过机械加工或最近通过使用3D打印，还原光聚合工艺进行的。这一过程能耗高，速度慢，负排放显著。它的规模也有限，无法生产大型零件。本项目提出通过多阶段、多材料同步模式和模具3D打印工艺，研究和开发可扩展且环保的大型零件工艺。该项目将调查与制造过程、材料开发、液体和浆液固化物理以及使用基于实时图像/扫描的方法相关的基本问题，以提供与能够生产精密铸件的集成制造系统相关的过程反馈和控制。这一过程的发展将为阿尔伯塔省的经济注入活力，通过提供目前在阿尔伯塔省无法获得的更安全、高效和高质量的金属部件制造技术，为先进制造业创造就业机会。

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.