3D Printed Patterns and Sand Casting

Home enthusiasts discuss their Foundry & Casting work.

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FKreider
Posts: 71
Joined: Fri Feb 02, 2018 8:44 pm
Location: Sturbridge, MA

3D Printed Patterns and Sand Casting

Post by FKreider » Fri Sep 27, 2019 9:27 pm

Thought I'd share a project I have been working on for the past few months, the future owner of the final part might be a member here on Chaski - not sure.

The original casting of this steam dome cover (goes on a British 7 1/4" gauge design called Paddington ) was found to be too small for the boiler as it was built. A larger casting is needed in order for the center bore to be the necessary diameter.
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Using the original drawings and casting for reference I re-drew the part in 3D CAD and then scaled it up to the required size. Getting the compound curves right proved to be quite a challenge. Once I managed to get it correct I turned it into a split pattern and 3D printed it. I also 3D printed a core box to go along with it.
IMG_8425.JPG
IMG_8430.JPG
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Ran out of metal on the first try, oops! However I managed to get a good pour the second time around! 8)
IDMK3951.JPG
FLMT57311.jpg
-Frank K.

steamingdon
Posts: 517
Joined: Sun Feb 22, 2009 9:21 pm
Location: massachusetts,usa

Re: 3D Printed Patterns and Sand Casting

Post by steamingdon » Sun Oct 06, 2019 6:52 pm

Nice job Frank.
steamer

mihit
Posts: 42
Joined: Wed Aug 22, 2018 1:04 pm
Location: Tai Tokerau, NZ

Re: 3D Printed Patterns and Sand Casting

Post by mihit » Mon Oct 07, 2019 12:54 am

So this is done for cope/drag greensand casting?
I have wondered about 3D printing for "lost wax/foam" type casts. Haven't had much to do with it.
Nice work though, piece looks good.

FKreider
Posts: 71
Joined: Fri Feb 02, 2018 8:44 pm
Location: Sturbridge, MA

Re: 3D Printed Patterns and Sand Casting

Post by FKreider » Mon Oct 07, 2019 2:02 am

steamingdon wrote:
Sun Oct 06, 2019 6:52 pm
Nice job Frank.
Thanks Don! :wink:
-Frank K.

FKreider
Posts: 71
Joined: Fri Feb 02, 2018 8:44 pm
Location: Sturbridge, MA

Re: 3D Printed Patterns and Sand Casting

Post by FKreider » Mon Oct 07, 2019 2:06 am

mihit wrote:
Mon Oct 07, 2019 12:54 am
So this is done for cope/drag greensand casting?
I have wondered about 3D printing for "lost wax/foam" type casts. Haven't had much to do with it.
Nice work though, piece looks good.
Yes exactly, split pattern with core and petrobond sand, petrobond gives a very fine surface finish vs. greensand. (At least this is what I have been told.)

Yes you are correct 3D printers are also very suited for making lost wax patterns! Dick_Morris's build thread has a very cool example of this process here:
http://www.chaski.org/homemachinist/vie ... 9&start=24
-Frank K.

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Gary Armitstead
Posts: 228
Joined: Sat Mar 02, 2013 12:35 am
Location: Burbank, CA

Re: 3D Printed Patterns and Sand Casting

Post by Gary Armitstead » Mon Oct 07, 2019 5:55 pm

I have been doing this for over two years now. I work with Marty Pinkston (FairWeather Foundry in Kent, Ohio). I design parts in MasterCam and Marty does the 3D printing for the pattern for the sand casting. It works great. So far only aluminum castings. But we are going to be doing other types of materials.
Gary Armitstead
Burbank, CA
Member LALS since 1980
Member Goleta Valley Railroad Club 1980-1993

FKreider
Posts: 71
Joined: Fri Feb 02, 2018 8:44 pm
Location: Sturbridge, MA

Re: 3D Printed Patterns and Sand Casting

Post by FKreider » Mon Oct 07, 2019 8:01 pm

I was looking at building a DIY RepRap around 2014 but decided I already had too many hobbies and at that time complete ready-to-run printers were expensive.

I purchased my printer last year and wished I had bit the bullet a few years back, besides making patterns it is great for prototyping parts.
-Frank K.

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