Additive Manufacturing for Casting: Fusion of Traditional And Modern Technologies

With the advent of additive manufacturing, commonly known as 3D printing, the entire manufacturing industry has undergone a major transformation. 

This innovative technology, which uses three-dimensional CAD data to create solid parts by accumulating materials layer by layer, has completely changed the production process from raw materials to products. 

However, despite its many advantages, additive manufacturing still faces limitations when it comes to producing large parts. To overcome this challenge, manufacturers are now combining traditional casting methods with 3D printing technology. 

This article explores how the integration of these two manufacturing technologies can increase production capabilities and open up new possibilities for various industries.

Limitations of additive manufacturing: 

Additive manufacturing is popular because it can directly produce various parts according to drawings without the need for mold making and machining, but its cost is relatively high, especially for high-melting-point metal castings, and using 3D printing to produce large parts can be time-consuming and expensive. In addition, the mechanical properties of 3D printed parts may not always meet the required standards. These restrictions limit the further promotion and use of additive manufacturing.

The role of traditional casting: 

For centuries, people have used traditional casting methods to produce large parts with excellent mechanical properties. Casting can produce complex shapes and intricate details that are difficult to achieve with other manufacturing technologies. By combining traditional casting with additive manufacturing, the advantages of both technologies can be utilized.

Additive manufacturing for traditional casting mainly involves two steps. 

First, a 3D printed pattern or wax pattern is created using additive manufacturing technology. The wax pattern is then used to make a shell mold after multiple coatings. 

Secondly, the molten metal is poured into the shell mold and solidified into the desired shape. 

This method combines the flexible production of 3D printing with traditional casting to quickly (without opening a mold) produce the required castings.

Advantages of combining the two: 

Combining traditional casting with additive manufacturing has multiple advantages. 

First, the application of 3D printing can produce parts that are difficult to produce or single or small quantities. The combination of the two technologies ensures that the final product meets the required mechanical properties and quality standards. 

In addition, this combination can enable foundries to optimize production processes by reducing delivery time and cost.

Applications and future possibilities: 

The combination of traditional casting and additive manufacturing opens up new possibilities for various industries. In the aerospace field, this combined method is used to produce complex engine components that require both complex designs and high strength. In the automotive industry, it can produce lightweight and durable parts. In addition, the medical field also benefits from this combination, which can manufacture customized implants and prostheses.

The combination of traditional casting methods and additive manufacturing has become a fundamental change in the casting industry. 

By combining the advantages of both technologies, foundries can overcome the limitations of additive manufacturing and produce large parts with excellent mechanical properties. This combined approach not only improves production capacity, but also opens up new possibilities for various industries. As technology continues to advance, the combination of traditional and modern technologies may become more common, thus completely changing the processing and manufacturing landscape.