Precision casting with 3D printing (SLA patterns)
Precision lost-wax casting is possible without the limitations of traditional pattern making: SLA 3D printed patterns can achieve complex, detailed geometries while simplifying the manufacturing process and reducing costs. Stratasys stereolithography 3D printing (SLA) offers a cost-effective, high-yield alternative to traditional processes.
What is precision casting?
Precision casting is a long-established method for producing metal parts with smooth surfaces and good dimensional tolerances.
The precision casting process uses lost-wax patterns and ceramic shell molds, which allow for the production of highly complex castings. Traditionally, these patterns have been made using wax pressing, which requires the use of metal tools. The significant cost and time required to produce wax pattern tools limits the economically competitive applications of casting.
However, manufacturers are recognizing the design freedom and cost savings offered by direct 3D printing and are moving away from traditional methods of producing die-cast patterns using CNC machining and wax pressing. Stratasys offers stereolithography 3D printing as a low-cost, high-yield alternative to traditional casting processes.
Advantages of 3D printed designs
- No high tooling costs
- High casting yield
- Faster production
- Good dimensional accuracy and shape retention
- Robust designs, easy handling/transportation
- Fast and easy iteration
- “Overnight printing” designs instead of weeks of CNC tooling
Stratasys stereolithography 3D printers are proven to produce high-quality, accurate and detailed parts with excellent surface finish. Designed by engineers for engineers, Neo is ideal for investment casting.
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Stratasys Neo Build Processor for Precision Casting
Together with Materialise, they have developed a new build processor software solution tailored for the Neo SLA 3D printer, improving the user experience and streamlining the workflow. Seamlessly integrated with Materialise’s Lattice module and e-Stage for Resin module, the build processor accelerates the preparation of files in Materialise Magics for the geometry of patterns required for precision casting, significantly reducing processing time without compromising the quality of the final part.
Somos® WaterShed® AF material
Somos® WaterShed AF (Antimony Free) is an antimony-free SLA substrate that enables low ash firing and meets the requirements of precision casting patterns. It can produce precise, complex patterns with excellent surface quality; there is no detectable antimony, making it safe for special alloys. Applications: precision casting patterns, aerospace, transportation, energy, templates and fixtures / operating aids, general prototyping.
Software, hardware and raw materials for SLA precision casting
Neo stereolithography 3D printers:
high precision, detail, excellent surface finish — ideal for master patterns.
Somos® WaterShed AF raw material:
antimony-free, low ash residue for fast shell production.
Neo Build Processor: up to significantly faster file preparation in Magics, with grid and support optimization.