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This comparison of core package designs illustrates the reduction of internal cores made possible by 3D printing technology.


from a timing standpoint. As a result no tooling was required


to manufacture the castings. Heavy use of computer aided en-


gineering was essential to accomplish a “right first time” casting and avoid the high cost of development using 3D printed sand molds. The castings produced passed all acceptance criteria including X-ray,


The conventional tooling method required seven core boxes to manufacture the thermal command center (only lower halves of blown core boxes shown).


dimensional checks and leak check testing. Furthermore, after machining the


parts, no defects were identified and machined castings were used and functioned without fault. Te cross-over point for this design was calculated. In addition, projections for smaller, complex castings indicate that the cross-over


point when soft tooling is more cost ef- fective than 3D printing may be in the hundreds of castings. Tis supports the adoption of the


technology into low-volume produc- tion castings. 3D printing of molds and cores also


offers flexibility in geometry design which cannot be produced by conven- tional tooling.


ERP Software specific for the cast metal industry All Inclusive Suite:


All Modules/Upgrades/Support =$120 per seat


USA: 800-323-2808 | lfuig sales@synchroerp.com | www.synchroerp.com 56 | MODERN CASTING May 2016


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