[3D Printing News] 3D Printing Casting of Metal Part Prototypes

[3D Printing News] 3D Printing Casting of Metal Part Prototypes

Sylatech, a lost-wax casting company, uses the Ultimaker 3D printer to accelerate their rapid prototyping process.
Sylatech provides CNC machining, RF and microwave machining, and investment casting services. They have over 53 years of history and possess expertise in aerospace, [and related fields].
Customers in industries such as aerospace, defense, medical, automotive, and construction.
Sylatech uses 3D printing as part of its lost-wax casting process. Before using the Ultimaker 3D printer , customers had to invest directly in the tools needed to manufacture specific metal designs. However, if modifications to their metal parts were required, this became a time-consuming and expensive process.
Using Ultimaker, prototypes can be completed before investing in tools for mass production, thus reducing the risk of such changes.


Accelerate the prototyping process

Using the Ultimaker 3D printer, Sylatech can create 3D printed models of customer designs within days.
It can be used directly to create a metal prototype. When modifications to the design are needed, the only additional cost is 3D printing the updated design.
The 3D-printed parts made of PLA provide accurate prototypes before creating individual metal parts.
Metal parts can be created using 3D printing. With Ultimaker, design engineers can have metal prototypes of their designs in as little as five days.

From 3D printing to metal parts

First, the 3D printed model is glued onto a wax frame. When the entire part contains multiple objects, they should be glued onto the wax frame as large as the dimensions allow. The wax frame is then placed in a container and filled with a ceramic solution called slurry. When the container is placed in an oven, the slurry hardens, and the 3D printed PLA model is completely melted and burned away.
This will then produce a mold for casting hot molten metal.


Attach the 3D printed object to the wax frame.

Once the metal inside cools, the mold breaks open. The metal parts are precise replicas of all the internal models and the original wax frame. The models can now be cut from the frame and smoothed by sanding. The metal parts are now ready for testing.


3D printing and metal prototyping by pouring liquid metal into a mold.

Cost savings and additional development time

To create a wax model, Sylatech must develop specialized tools. Projects that typically use these tools directly will take five weeks to develop the first metal part.
Adjusting the tool when modifications are needed during design development costs approximately £500 per adjustment. However, when using Ultimaker, the cost of printing a new design is only [amount missing] per piece.
Around 10 pounds.
Typically, 30% of designs require changes after the first prototype. Creating metal prototypes using Ultimaker minimizes the need for tool modifications. Therefore, this saves not only significant time but also costs.

The use of 3D printing has significantly changed the way we conduct business.
We will continue to use 3D printing and Ultimaker to benefit our customers.


3D printed prototypes and fully assembled final models

Sylatech uses Ultimaker

Sylatech has started using 3D printers with Ultimaker 2+ .
Using the printer yielded excellent results from the start. They placed their model onto the Ultimaker Cura printing platform, which immediately prepared their design file into an accurate 3D print file.
After successfully using Ultimaker 2+, Sylatech invested in Ultimaker 3. The water-soluble PVA material enabled Sylatech to print a wide variety of designs desired by its clients.

In addition to printing prototypes for clients, Sylatech uses their 3D printers to create a variety of jigs, tools, and robot parts. They have several robotic arms that automate much of their CNC machining process. Many parts for these robotic systems are printed using Ultimaker 3D printers.


Sylatech robot electronic housing; Sylatech custom robot pneumatic components

Sylatech is a prime example of how Ultimaker can be used as a tool to benefit a company. They have successfully optimized their lost-wax casting process and used 3D printers to help achieve other workflow improvements. Most importantly, through Sylatech's application of Ultimaker technology,
Customers can directly benefit from cost savings and receive the final metal parts in the fastest possible time.

Original link:https://ultimaker.com/en/stories/52481-casting-metal-parts-for-prototyping-from-3d-prints