RE: QuickCast in a hurry

Date: Fri Mar 26 1999 - 11:40:36 EET

A lot of the problems on answering your question relates to the

complexity of the casting. I can give you a recent example although

this is not necessarily always the case.

We have just completed a very complex core model for a one off casting,

to produce the pattern in the traditional way, the core box and first

sand core would have cost in the region of 12k and would have taken

approximately 3 weeks to complete. Using our sand sintering machine

(EOS-S) we completed the sand core in 4 days at a cost of about 1k.

As I said earlier this is not always the case. One other thing that has

to be taken into account is that this process gives you the same

problems as Investment Casting, that being you only have one pattern,

so if you have any problems at the foundry you have to manufacture

another model, unlike having a core box made where you have a very

quick way of producing replica cores quickly and cheaply, unless you

have forseen a possible problem and built 2 models at the same time if

bed capacity allows. There is also a problem with out-gassing on

sintered cores, as long as the foundry is aware of this they should

have no problems in working with this process, but this has to be

thought about if you want to use this route effectively. I hope this

goes someway to answering your question.

Graham Tromans
Rover Group

-----Original Message-----
From: tomr

Sent: Thursday, March 25, 1999 8:05 PM
To: graham.tromans
Cc: tomr; rp-ml
Subject: RE: QuickCast in a hurry

Yes, shell molds from SLS are certainly a way to go.

How does the cost of an SLS sand mold compare with the cost of an RP

for shell molding, either of which is destroyed in the making a single


At 12:36 PM 3/25/99 +0000, you wrote:
>I think I may have missed the earlier parts of this thread, so I do


>fully understand your requirements. One solution we have used for

>parts in small quantities that would normally require a pattern set to

>be made, is to use the Sand Sintering process. We find most foundries

>have no problem with this, because you supply the full sand set and

>they just pour it. No draft angles required.
>Graham Tromans
>Rover Group

>-----Original Message-----
>From: ATiburon

>Sent: Thursday, March 25, 1999 2:44 AM
>To: tomr
>Cc: ATiburon; rp-ml
>Subject: Re: QuickCast in a hurry
>In a message dated 99-03-23 11:25:14 EST, you write:
><< >> Dan: We pour ductile iron (3-1/2 weeks) from RP patterns

>(1-week). >>
>As I understand, ductile iron, is done more commonly in sand casting.

>patterns need to be either designed for that process, or converted into
>patterns that would work, as a matchplate for instance. Most sand

>foundries aren't geared towards prototype work though. That is the

>process I
>would investigate rather than investment casting.
>Andy Scott
>Lockheed Martin Aerospace
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