This project seeks to develop and demonstrate fast 3D sand printing technology hardware that would be affordable to small and medium-sized enterprises while developing a knowledge-base of design rules to enable design optimization in metal casting to reduce overall manufacturing costs.
3D sand printing can enable new casting designs with reduced mass, part consolidation, and complex fluid flow channels. Mass manufactured vehicle optimization efforts, including those for improved fuel economy and lower emissions, would benefit from additive manufacturing (AM) sand printing. Two key barriers to the adoption of AM sand printing in the industry of metal casting production operations are (1) slow process speeds and (2) high cost, both capital and consumables.
Three areas of opportunity to improve AM application for full production of castings in this project include:
- Demonstration of fast printing technology hardware that is affordable to the domestic metal casting supply chain;
- Development of knowledge-based design rules; and
- Execution of industry-valued workforce outputs to accelerate widespread technology applications and support regional manufacturing systems integration.
This project will accelerate the development of fast printing technology hardware that is affordable to the domestic metal casting supply chain. Designed hardware must work with open-source bonding resins and aggregates to reduce operational cost of emerging hardware assets. Software development must augment emerging hardware advances. UNI and PSU will advance knowledge-based design rules development to facilitate engineer design optimization work. Ideally, these design rules would be integrated into legacy software applications.
Other Project Participants
- Youngstown State University
- University of Northern Iowa (UNI)
- American Foundry Society
- Tinker Omega Manufacturing LLC
- Penn State University (PSU)
- Humtown Products
- North East Iowa Community College (NICC)
- Product Development & Analysis (PDA) LLC
- U.S. Department of Defense
- National Science Foundation
- U.S. Department of Energy