Design carries a small upfront but signifi cantly large long-term impact on product cost.
6 7 8 9
Additive manufacturing opens unique design freedoms. Fillets and radii are always pos- sible, machining a relief area can be incor- porated easily, no draft requirements leads to lower weight, and cores can be eliminated where used due to back draft.—Shah
Isolated hot spots can be fed with spot risers. —Shah
Calculating Cost
Bottom gating is possible for uniform fi lling with the least turbulence.—Shah
10 11
Designers don’t have to account for core split lines, flash or veins. There is flexibility with the placement of feeding aids such as chills, risers, filters, gates, in-gates, and zircon facing cores.—Shah
12
Factor reasonable risk into the price.—Weiss
Hybrid approaches can be utilized for time and/or cost savings. T is means conventional patterns used with 3-D printed cores. For 1,000 parts or higher, hybrid
is more cost eff ective than 3-D sand printing for parts with a complexity
factor of 56 or higher.—Brett Connor, Youngstown State University
When patternmaking requires expensive tooling, 3-D sand print- ing is advantageous for low quantity production of molds and cores, even for low complexity parts. T e cost advantage depends on sand printing production costs.—Connor
January 2017 MODERN CASTING | 27
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