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

铸造是金属零件生产中使用的基本制造工艺。铸造件在阿尔伯塔的许多行业中得到广泛应用。铸造工艺中的基本步骤是生产图案，然后构造模具，这通常通过机械加工或最近通过使用3D打印、瓮光聚合工艺来进行。这一过程是高度能源密集型的，并且缓慢，具有显著的负排放。它的规模也有限，无法生产大型零件。该项目提出通过多阶段，多材料同时图案和模具3D打印工艺，研究和开发大型零件的可扩展和环保工艺。该项目将研究与制造工艺、材料开发、液体和浆料凝固物理学相关的基本问题，以及使用基于真实的时间图像/扫描的方法来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。这一工艺的发展将振兴阿尔伯塔省的经济，通过提供目前阿尔伯塔省没有的更安全、高效和高质量的金属零件制造技术，在先进制造业中创造就业机会。

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.