Inside ICI Continued from pg 8


A Collaborative Effort The IMPACT I project is built on the contributions of a diverse team of participants, each bringing unique expertise to the initiative: Printing: These member companies


are leaders in the field of ceramic AM- technology. They provide printed shells as well as material and equipment: • Intrepid Automation, San Diego, CA • Rangeview, Inc., El Segundo, CA • Tethon 3D, Omaha, NE


Foundries: The participating


member foundries bring hundreds of years of aluminum, steel and nickel- based alloy casting experience to the project. Each has experience using other AM technology in their business. • Barron Industries, Inc.: Oxford, MI - A356


• Bescast, Inc.: Willoughby, OH - IN-625


• Kovatch Castings, Inc.: Uniontown, OH - A356


• Metaltek International – Wisconsin Investcast Division: Watertown, WI - 316L


• O’Fallon Casting: O’Fallon, MO - A356


• SeaCast, Inc.: Tulalip, WA - IN-625 Vacuum Melted


• Shellcast, Inc.: Montague, MI - IN-625 + 316L


• Signicast, LLC: Milwaukee, WI - A356


Universities:


• Alfred University – Center for Advanced Ceramic Technology: Conducts ceramic material testing


• Missouri University of Science and Technology: Provides advanced, high temperature in-situ measurement technology that supports simulation and casting quality improvements


• University of Arizona: Provides material property research and testing and CT capability


Technology Support:


• Foundry Support Operations: Provides investment


10 ❘ February 2025 ® casting expertise


• Product Development & Analysis, LLC: Provides simulation modeling expertise


• Concurrent Resources, LLC: Provides project management, additive manufacturing expertise, dimensional analysis, and CAD design


The Project The process begins with foundry teams designing the casting and gating system, setting critical parameters for a successful pour. To ensure optimal performance, PDA runs simulation analyses to predict material behavior, while service bureaus evaluate whether the design is suitable for direct printing. Once the printability is confirmed, a final mold design review brings together the participants to verify the shell's integrity before production begins. With the design finalized, service print


bureaus the ceramic at each foundry shell—


eliminating the need for the traditional multi-layer dipping method. Once printed, the shell undergoes rigorous inspection


ensuring


it meets all necessary structural and quality requirements before moving on to the casting stage. The foundries then use the printed shells to cast molten metal into the prepared molds. The completed castings undergo non-destructive testing (NDT) to detect external and internal defects, followed by dimensional inspections to confirm precision and consistency.


Above photo courtesy of Shellcast, Inc.


AMS-2175A is the guiding inspection specification for the project. The final stage involves a deep dive into performance evaluation. A cross- disciplinary team analyzes the results, focusing on shell durability, metallurgical integrity, and overall casting success. Alfred University conducts ceramic testing, ensuring the printed shells meet industry standards. The University of Arizona leads metallurgical testing, assessing the quality of the cast metal. Meanwhile, Missouri University of Science & Technology (MUS&T) collects thermophysical data, studying how the


material behaves under extreme temperatures.


By the end of this phase, the IMPACT project aims to provide a roadmap for integration of AM technologies into the investment casting industry at large.


Conclusion: A Model for the Future The ICI IMPACT project shows what can be achieved when industry, academia, and government come together to tackle shared challenges. Advanced ceramic AM materials


have the potential to set new benchmarks for efficiency, reliability, and scalability in the investment casting industry. As the U.S. prioritizes the modernization of its industrial base, projects like IMPACT are paving the way for a more resilient and capable manufacturing ecosystem. If you want to learn more about the project, the project leads will be presenting at AM4IC in Dayton, Ohio this June.


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40