Rapid Manufacturing of Cast Metal Parts

R. Aliyev, D. Gantner (ACTech GmbH Freiberg, Germany)

ABSTRACT

It’s been more than 15 years since the first prototype manufacturer was presented. Since then many industrial viable Rapid Prototyping (RP) methods have been developed and successfully proved in practice. While the manufacturing of plastic prototype parts was developed using a wide spectrum of technologies the situation regarding manufacturing of metal prototypes was not progressed. One problem was not all prototyping methods commercially available guaranteed properties close to the final series parts. Now, the sand casting prototype method offers an alternative possibility for rapid manufacturing of functional parts with all the required properties.

The R&D department within ACTech GmbH were given the task in the development of accelerated methods of prototype manufacturing. This was achieved with the development of methods for the direct production of sand molds. This method enables the metal prototype to be fabricated within significantly reduced time frames. An important precondition is the using of high speed milling technology.

In this paper the principles of this methods are described and examples included to explain the overall potential.