by Emily Newton
Many manufacturers are turning to 3D printing as an alternative to conventional production methods. In some cases, though, this technology is best when combined with more traditional processes. Implementing 3D printing in sand casting is the perfect example.
Sand casting typically involves making component replicas through machining or hand-molding soft materials. 3D printing these components before forming sand molds around them yields several important benefits. Here are five of these advantages and how companies can make the most of them.
1. Faster Turnaround Times
The most immediately recognizable benefit of 3D printing in sand casting is that it’s faster than subtractive replica-making methods. Additive manufacturing can produce complete patterns in a matter of hours, whereas conventional alternatives may take days or even weeks.
Part of that speed comes from the fact that 3D printing produces usable patterns in fewer steps. Fewer changeovers between equipment reduce wasted time. Depositing material is also faster than cutting it away, as it requires less resistance and energy.
These speed improvements mean you can move on to molding and casting in less time. Consequently, your overall lead times shrink, enabling a faster time to market, quicker shipping timelines and higher production volumes.
2. Lower Costs
Relatedly, additive manufacturing can also make the casting process more affordable. Solid sand casting is already one of the most popular casting methods for its cost-efficiency. 3D printing takes this further by reducing production costs before molding and pouring.
Because 3D printing replicas take less time, it incurs lower workforce-related costs. It’s also easily automatable, letting you place employees elsewhere to accomplish more work in a given time frame. Removing the need for additional preparation or post-processing tasks further cuts expenses.
3D printers are also highly energy-efficient. As a result, using these instead of CNC mills or other conventional equipment can lower utility costs. These savings are even more impressive when considering the higher throughput you can achieve, leading to more profitability.
3. New Design Possibilities
Another advantage of additive manufacturing in sand casting is that it lets you cast designs that would otherwise be impossible or impractical. 3D printing is more versatile than subtractive alternatives, enabling a wider range of pattern designs.
3D printers are precise and their nozzles can move to deposit material at virtually any angle. Consequently, they can produce complex lattices and other detailed structures you can’t get by cutting away material. In some cases, designs may be possible with subtractive methods but would be too inefficient to be practical. 3D printing’s speed makes these patterns viable.
This design versatility lets you bring the cost-effectiveness and reliability of sand casting to more components and products. Alternatively, you could design innovative, unique products to stand out in crowded markets.
4. Higher Part Quality
The same precision that enables these innovative designs also leads to higher-quality replicas. The closer these patterns reflect the optimal component, the more reliable the sand casting process will be.
3D printing further improves quality by minimizing worker involvement. Once you initiate a print, the printer handles the rest of the process autonomously. This automation means there’s no room for human error to occur, eliminating mistakes from distraction or lapses in judgment.
Without this assurance, errors could arise in the pattern-making process. These mistakes, in turn, lead to defective molds. Correcting these defects becomes increasingly time-consuming and costly the further they go through production. 3D printing prevents them earlier and minimizes this disruption.
5. Improved Traceability
Its traceability is a less obvious but still crucial advantage of 3D printing in sand casting. 3D printers can deposit unique markers, time stamps or numbers on each pattern they produce. You can use them to track individual components throughout production.
In a perfect world, component traceability would never be necessary. However, errors can still arise. When they do, it’s important to understand what led to them so you can address it effectively and prevent future mistakes. Looking at a part and seeing details on its production provides that visibility.
This traceability is particularly important for upstream suppliers of downstream manufacturers. A staggering 45% of supply chain leaders say they have no visibility beyond their first-tier suppliers, limiting their auditability and error response. 3D printing manufacturing data on specific components addresses this obstacle.
Best Practices for Implementing 3D Printing in Sand Casting
It’ll take a few best practices to experience these benefits to their fullest. The first and one of the most important is to choose the right kind of 3D printing technology for the job at hand.
Filament-based printers are the most common in many circles, but resin printers can deposit material up to 10 times faster, depending on the design and medium. Pebble printers are a newer, more affordable alternative, especially on a larger scale. Which of these is best depends on your needs, budget and materials.
Similarly, some materials are better than others for sand casting purposes. High-performance polymers are more expensive but hold up to more wear and have a better finish, making them superior in most cases. However, you may be able to use cheaper, low-temperature polymers if you need a wider variety of molds and require less surface detail.
Sometimes, it’s best to use 3D printing for the entire production process. By the same token, conventional approaches are still preferable for some jobs.
3D printing-assisted sand casting is ideal for complex parts that need the strength of more solid metals. Plastic components are best to 3D print from start to finish. Conventional sand casting is the way to go for simple designs with high strength requirements.
3D Printing Revolutionizes the Sand Casting Process
Additive manufacturing is a revolutionary technology, but that doesn’t mean you need to replace everything all at once. Sometimes, a hybrid approach is best, like 3D printing in sand casting. Combining these methods can yield significant time, cost and design improvements.
Many manufacturers can benefit from 3D printing in some capacity if they’re willing to embrace new technologies. Learning about its benefits in sand casting and ideal use cases is the first step in capitalizing on this exciting new technology.
