66th Annual Technical Conference & Exposition WEDNESDAY, OCTOBER 30, 2019

8:00 a.m. – 8:05 a.m.

8:05 a.m. – 8:50 a.m.


Paper No. 14: 3D Printed Inserts and Mold Cavities that Can Be Used for Producing Wax Patterns Jacob Lehman, CMfgE, Pittsburg State University Traditional investment casting wax tooling is often expensive to produce and time consuming to design and manufacture. This paper will explore the use of inexpensive 3D printed tooling to produce wax patterns for investment casting. Printed mold cavities can be produced very quickly using additive manufacturing compared to traditional methods for mold and die manufacturing.

This investigation examines both

printed mold cavities and inserts produced on an inexpensive 3D printer as a supplement to traditional tooling, especially for low volume production runs.

8:50 a.m. – 9:35 a.m.

Paper No. 15: Autonomous Quality Control: The Future is Now Rahul Alreja, VJ Technologies Inc., Booth 334 In today’s world, delivering quality products to end- users is absolutely critical. Social media and the internet have made knowledge instantaneous and pervasive, and a misstep or flaw can cause catastrophic damage to a company – reputations that have taken years to make can come crashing down in days, if not hours.

The trick, then,


9:35 a.m. – 10:20 a.m.

Paper No. 16: An Evaluation of Using a Low-Cost 3D Printer for Prototype Investment Casting Patterns

Aaron Meyer, Wisconsin Precision Casting Corp. Wisconsin Precision has always been proactive in using printed patterns to speed the delivery of prototype and low volume investment castings. For the majority of our experience, we have purchased printed patterns rather than bringing pattern printing capacity in house. Occasional delay in receiving patterns due to backlogs at service providers limited our ability to consistently meet delivery promises to our customers. In 2019, Wisconsin Precision installed a low cost (relative to other pattern printing technologies) material extrusion printer running a filament specifically formulated for investment casting patterns. The printer was used to print patterns for prototype castings, low volume casting orders, and for some tooling applications such as setters. In this paper, the printer and filament are evaluated relative to more common printed patterns in areas including accuracy, surface roughness, cost, speed, and ease of casting. In ease of casting such issues as shell cracking, burnout, and residual ash will be evaluated.

10:20 a.m. – 10:35 a.m.

10:35 a.m. – 11:20 a.m.

The challenge is that maintaining quality is not easy – there are too many variables at play, even in the cleanest of environments. And conditions can change almost instantaneously.

is to be adaptable, and emerging technologies (such as Big Data and Blockchain) are being adopted and harnessed to dynamically (and automatically) alter quality. Drawing upon some real-world examples from different industries, this session will explore the future of quality.


Paper No. 17: Digitization & Automation of the Process of Printing Patterns for Investment Casting Ben Wynne, Intrepid Automation, Booth 144 While tremendous progress has been made in

using printed patterns to create production quality investment castings, the manual steps required in all current pattern printing technologies effectively prevent them from being seriously considered for all but very low volume production.

The manual steps increase Join the

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the time required to create patterns as well as slow potential production rates. This study examines an effort to automate the pattern printing process using multiple printers and robotic handling to create a system that can create patterns with no manual steps, runs unattended for days at a time and demonstrates production rates that rival molded wax patterns. This is further expanded with new materials that

process better through a foundry enabling a more ‘wax like’ workflow to be realized. The digitization of pattern production we believe is the next major evolution in foundry solutions and can offer faster turnaround of finished castings, less upfront cost and new non-moldable geometries (think generative design, topology optimization etc) to become more mainstream.

30 ❘ October 2019 ®

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