Casting Tool Demonstrator

Casting tool demo with steel
Figure: Casting tool demo manufactured out of Stainless Steel with internal cooling channels of diameter 4 mm ,2 mm, 1 mm & 0.5 mm

The casting tool demonstrator (CTD) is a perfect example of how AM enables possibilities that have been until recently difficult to realise – or perhaps even not possible with the conventional manufacturing techniques. The above CTD has been manufactured out of Austenitic 316L Stainless Steel and can be used for the casting of Aluminium. 

The internal channels for the coolant mitigate any deformation and failure of the part during the casting process and can be printed with diameters as small as 500μm. The part contains diameters ranging from 4 mm to 0.5 mm and required a printing time of around 9 hours on an FDM printer. Following the printing, the part was subjected to green machining, to improve surface finish, and was sintered in pure hydrogen atmosphere to obtain a part with over 99% relative density – comparable to processes like Selective Laser Melting (SLM) – and geometrical tolerances  of  <50μm.

Have an idea where such a manufacturing approach can help save costs and improve product quality? Then you know the drill! (Hint: Contact>Fill Form)

Figure: (Left) Different phases of printing & (Right) Porosity analysis for the material with density specimens