Inside Track - Tech Apps: Green Sand Casting

The most important factors to consider when orienting the STL in Insight/Catalyst are part compressive strength and surface finish. Part compressive strength refers to the ability of the printed part to withstand compressive forces without breaking or deforming. Surface finish refers to the quality and smoothness of the outer surface of the printed part. Both of these factors are crucial in determining the overall strength and aesthetics of the printed part. Therefore, the correct answer is A & B.

FDM green sand casting patterns have been tested up to 1700psi using ABS-M30 (solid parts). This means that the patterns made using this method and material have been subjected to pressures as high as 1700psi without any issues or failures. This information is important for determining the strength and durability of the patterns and ensuring that they can withstand the pressures experienced during the casting process.

FDM (Fused Deposition Modeling) is a 3D printing technology that uses a thermoplastic filament. It is best suited for green sand casting, which is a type of sand casting that uses a mixture of sand, clay, and water. This type of sand casting is commonly used in the foundry industry due to its low cost, good dimensional accuracy, and ease of use. FDM technology can be used to create patterns or molds for green sand casting, allowing for the production of complex shapes with high precision.

The typical benefits of FDM (Fused Deposition Modeling) compared to traditional processes for sand casting patterns include significant time and cost savings, as well as the ability to quickly make design and iteration changes. FDM also allows for low-volume jobs, making it a versatile and efficient option for sand casting patterns. Therefore, the correct answer is "All of the above."

For draws greater than one inch (25.4mm), it is recommended to increase the width of all features to larger than 0.5” (13mm).

ULTEM 9085 may be best suited when high compressive forces are used in the molding process. This material is known for its high strength and stiffness, making it capable of withstanding high pressures without deformation or failure. It also has excellent heat resistance and chemical resistance, further enhancing its suitability for applications that require high compressive forces. ABS-M30, ABS-M30i, and PC-ABS may not be as suitable as ULTEM 9085 in terms of their ability to withstand high compressive forces.

All of the mentioned finishing techniques (auto body fillers, hand sanding, and Finishing Touch Smoothing Station) are acceptable for FDM green sand casting patterns. This means that any of these techniques can be used to achieve the desired finish on the patterns.

Traditionally, green sand casting patterns were manufactured by CNC machining them from wood or metal. This process involves using computer-controlled machines to accurately shape the patterns according to the desired design. CNC machining offers precision and consistency, making it a preferred method for creating intricate patterns. Hand carving from wood is also a traditional method, but it may not provide the same level of accuracy and efficiency as CNC machining. SLA systems, on the other hand, are not traditionally used for manufacturing green sand casting patterns.

All of the above build styles are best suited when mechanical compression of the green sand is used. The custom sparse setting allows for flexibility and customization, the sparse double-dense setting provides a balance between strength and porosity, and the solid setting ensures maximum compression and minimal porosity. Therefore, all three build styles are suitable for mechanical compression of green sand.

The recommended top coats for aiding mold release are Master Foundry – Kote and any standard top coat used for wooden patterns. Both options C and D fulfill this requirement. Primer paint and silicone lubricant are not specifically mentioned as recommended top coats for aiding mold release.