Rapid Freeze Prototyping and Investment Casting Application

Missouri University Of Science And Technology, Rolla MO

Investigators

Abstract

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.