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<p>The lost foam casting process offers significant advantages, including the elimination of parting lines and cores, leading to reduced machining and material waste. However, the traditional method of creating foam patterns involves expensive and time-consuming tooling, which limits the process’s flexibility and cost-effectiveness, particularly for low-volume production and rapid prototyping. 3D printing emerges as a transformative solution to these challenges, allowing for the direct fabrication of complex lost foam patterns without the need for traditional tooling. Despite these advancements, a significant knowledge gap remains in the selection of appropriate materials for 3D-printed patterns. Sixteen 3D printable materials were assessed for use as expendable printed patterns using thermogravimetric analysis (TGA) and casting trials. Variants of polyethylene performed the best in TGA and casting trials but face printing challenges. High-impact polystyrene (HIPS) was designated the best overall and shown to be improved further with plasticizers and foaming agents.</p>

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Optimizing 3D Printable Filaments for Printed Expendable Patterns in Lost Foam Casting

  • 期刊论文

  • 发表日期：

    2025年6月17日

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  • Jacob A. Belke,
  • Sean M. Frank

摘要

The lost foam casting process offers significant advantages, including the elimination of parting lines and cores, leading to reduced machining and material waste. However, the traditional method of creating foam patterns involves expensive and time-consuming tooling, which limits the process’s flexibility and cost-effectiveness, particularly for low-volume production and rapid prototyping. 3D printing emerges as a transformative solution to these challenges, allowing for the direct fabrication of complex lost foam patterns without the need for traditional tooling. Despite these advancements, a significant knowledge gap remains in the selection of appropriate materials for 3D-printed patterns. Sixteen 3D printable materials were assessed for use as expendable printed patterns using thermogravimetric analysis (TGA) and casting trials. Variants of polyethylene performed the best in TGA and casting trials but face printing challenges. High-impact polystyrene (HIPS) was designated the best overall and shown to be improved further with plasticizers and foaming agents.