Investment Cast Biomedical Implants From Rapid Prototyping and Tooling Techniques

2000 ◽  
Author(s):  
K. P. Walsh ◽  
D. G. Boyle ◽  
D. I. Wimpenny
Keyword(s):  
Rapid Prototyping ◽  
Investment Casting ◽  
Casting Process ◽  
Lead Times ◽  
Biomedical Implants ◽  
Contributing Factors ◽  
Investment Cast ◽  
Wax Pattern ◽  
Prosthetic Implant ◽  
To Receive

Abstract Traditionally investment casting of biomedical implants has utilized the lost wax process, this paper is an investigation into the possibilities of casting small lots of custom specific medical implants directly and indirectly from various rapid prototyping & tooling techniques. Small batch quantities for quick turn arounds cost and lead times are the main contributing factors for the purpose of this investigation. To directly produce parts means that a RP model will be used in the place of the wax pattern in the investment casting process. To indirectly produce parts means that a mould, which has been generated from RP&T techniques, will be used to manufacture wax patterns that will then in turn be used to investment cast the parts. The device to be manufactured is a non-sterile, referred to as ‘trial’ prosthetic implant. The implant is used by the operating surgeon to check the ‘fit’ of the cavity that will be made to receive the prosthesis plus bone cement that will be used to fix the implant in place.

Replication of Microscale Features via Investment Casting Using the Example of an Aluminium Intake Manifold of a Gasoline Engine with an Inner Technical Shark Skin Surface

2009 ◽  
Vol 618-619 ◽  
pp. 581-584
Author(s):  
Todor Ivanov ◽  
Andreas Bührig-Polaczek ◽  
Uwe Vroomen
Keyword(s):  
Investment Casting ◽  
Gasoline Engine ◽  
Casting Process ◽  
Skin Surface ◽  
Micro Milling ◽  
Intake Manifold ◽  
Shark Skin ◽  
Functional Surfaces ◽  
Wax Pattern ◽  
Investment Casting Process

Within the project “Functional Surfaces via Micro- and Nanoscaled Structures” an investment casting process to produce 3-dimensional functional surfaces down to a structural size of 1µm on near-net-shape-casting parts will be developed. The common way to realise functional microscale features on metallic surfaces is to use laser ablation, electro discharge machining or micro milling. The handicap of these processes is their limited productivity. In order to raise the efficiency, microscale features will be replicated by use of the investment casting process. The main research objective deals with the investigation of the single process steps with regard to the moulding accuracy. Actual results concerning making of the wax pattern and the ceramic mould as well as the casting of an Aluminium alloy will be presented. By using the example of an intake manifold of a gasoline race car engine a technical shark skin surface was defined in order to reduce the drag of the in-coming air. Possible process stategies to realise microscale features on an inner surface of a casting part were developed.

Study of Shell Cracking Behavior and its Remedies in Investment Casting Process Using Quick Cast Rapid Prototype Polymer Patterns

2012 ◽  
Vol 710 ◽  
pp. 214-219
Author(s):  
Ankit Sharma ◽  
Mayukh Acharya ◽  
Alok Agarwal ◽  
Govind ◽  
S.C. Sharma ◽  
...  
Keyword(s):  
Rapid Prototyping ◽  
Investment Casting ◽  
Rapid Prototype ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Cost Effective ◽  
Direct Conversion ◽  
Cracking Behavior ◽  
Engineering Changes ◽  
Investment Casting Process

Investment casting has emerged as the foremost casting process for manufacturing of intricate parts where better dimensional accuracy is required. Use of rapid prototyping polymer patterns is one of the major advancements in investment casting process. Elimination of die making step as required in the traditional wax process makes it quicker and a cost effective process. The direct conversion of 3D CAD data into rapid prototyping pattern decreases development time, chances of costly mistakes, minimizes sustaining engineering changes and extend product lifetime by adding necessary features and eliminating redundant features early in the design.

scholarly journals CERAMIC CORES FOR TURBINE BLADES : A TOOLING PERSPECTIVE

2013 ◽  
pp. 93-99
Author(s):  
PRADYUMNA R ◽  
BAIG M A H
Keyword(s):  
Investment Casting ◽  
Turbine Blades ◽  
Casting Process ◽  
Ceramic Core ◽  
Pin Fin ◽  
Investment Cast ◽  
Investment Casting Process ◽  
Forced Cooling ◽  
Super Alloy ◽  
Ceramic Mix

Blade/vane components used in aerospace turbines are of twisted aerofoil shape, made by the process of investment casting, using Ni based super-alloy materials. These castings operate at turbine inlet temperatures (TET) close to the melting point of the alloy, in order to maximize thermal efficiency and thrust of the engine. The castings are made hollow, with intricate features such as turbulator, pin-fin, etc built-in to maximize the effect of heat transfer during forced cooling through internal passages. The hollow geometry in the castings is produced during the investment casting process by using a suitable ceramic core made from Silica or Alumina based mixes. These ceramic cores are high pressure injected by forcing the ceramic mix into dedicated molds or dies. Development of such dies is an involved process by itself, addressing issues right from ceramic mix behavior to manufacturability of the injection mould. The present paper attempts to highlight issues related to tooling development for ceramic cores used in investment cast turbine blade/vane components.

The Influence of Injection Processing on the Shrinkage Variation and Dimensional Stability of Wax Pattern in Investment Casting

2012 ◽  
Vol 538-541 ◽  
pp. 1217-1221
Author(s):  
Dong Hong Wang ◽  
Bo He ◽  
Fei Li ◽  
Bao De Sun
Keyword(s):  
Dimensional Stability ◽  
Investment Casting ◽  
Flow Direction ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Cast Part ◽  
Injection Process ◽  
Wax Pattern ◽  
Dimensional Variation ◽  
Wax Injection

The accuracy of the wax patterns used in the investment casting process has a direct bearing on the accuracy of the final cast part. Wax injection process plays a key role in production of nearly net shape wax pattern. Dimension shrinkage is one of the most significant problems of a wax pattern in terms of dimensional stability in the wax injection molding. This study aimed to determine the effects of injection parameters on the dimensional accuracy of the wax patterns. Linear contractions normal to flow direction and weight of wax patterns were measured and dimensional variations were evaluated. The results highlight it is important that when dealing with thick gates, short packing time appears to be the best way to avoid gate area over packing and dimensional variations, high packing pressure appears to increase expansion and dimensional variation of wax pattern.

scholarly journals Pembuatan prototipe Aluminium cylinder head engine dengan metode rapid prototyping dan investment casting

2021 ◽  
Vol 10 (1) ◽  
Author(s):  
Masy'ari Masy'ari ◽  
Ari Dwi Prasetiyo ◽  
Edi Karyadi
Keyword(s):  
Economic Growth ◽  
Rapid Prototyping ◽  
Investment Casting ◽  
Cylinder Head ◽  
Computer Aided Design ◽  
Manufacturing Industry ◽  
Casting Process ◽  
Silica Sand ◽  
Gating System ◽  
3D Printed

The manufacturing industry is one of the sectors that consistently continues to provide the largest national economic growth contribution to reach the target economic growth of 5.3% in 2020. In the 4.0 industry era, the manufacturing industry sector in Indonesia starts to adopt the newest digital technology like artificial intelligence, machine learning, and the internet of things, and additive manufacturing. This research aimed to develop a manufactured product in form of Aluminium cylinder head engine prototype with digital rapid prototyping and Aluminium investment casting. To reach the research goal, the research started from theoretical study and data collection. Next, the cylinder head engine is modelled in CAD (computer-aided design software and printed in 3D printer with polyvinyl butyral and polylactic acid. This 3D printed cylinder head is going to use as moulding pattern. Hereafter, the cylinder head engine is assembled with gating system and coated with a mix of cement plaster, silica sand, and kaolin soil. After the mould is dry, the mould will be burned until the 3D printed pattern is vaporized. The final step is pouring the molten Aluminium at 800°C temperature into the mould. The results showed that the casting process with a cylindrical gating system was perfectly formed, especially for the fins part. However, for the smaller fins, there were still defects in form of lumps. The mix of silica sand, gypsum cement and kaolin soil can create a strong mould. The difference in pattern material does not have a significant effect on the investment casting mould-making process.Keywords: Rapid prototyping, cylinder head engine, investment casting.

Dimensional Accuracy of the Molds Built on Rapid Prototyping under the Influence of the Investment Casting Heat Processes

2013 ◽  
Vol 371 ◽  
pp. 188-192
Author(s):  
Adrian Coman ◽  
Simona Rodean ◽  
Dănuţ Vasile Leordean ◽  
Carol Patalita
Keyword(s):  
Heat Transfer ◽  
Injection Molding ◽  
Rapid Prototyping ◽  
Investment Casting ◽  
High Efficiency ◽  
Dimensional Accuracy ◽  
Popular Method ◽  
Wax Pattern ◽  
Heat Processes ◽  
Wax Injection

t is well known that the Investment Casting (IC) processes automatically involves wax and molds as a first step. During the wax injection there are heat transfer between the wax pattern and mold. The mold is getting heat and due to this, the dimensional accuracy suffers in the not desirable way. Injection molding has been the most popular method for making wax products due to high efficiency and manufacturability.

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