ZCastTM Direct Metal Casting
Data to Cast Metals in 12 Hours
Agenda
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3DPTM Process Outline and History
Z Corporation
Griffin Industries
Overview of ZCast Direct Metal Casting
Process Performance and Advantages
Case Studies
Future Development Objectives
3DP Process Outline and History
• Process
– Creation of three dimensional parts (or molds for parts)
by building and stacking hundreds or thousands of very
thin layers
– Each layer is created by jetting a binder or solvent into
a thin layer of powdered material
– Each layer is supported during the building process by
the powder layers below
– 3DP can create any geometry in a wide variety of
materials
Description of 3DP Process
Build
Piston
Powder
Source
4
Description of 3DP Process
Roll One Layer
of Powder
5
Description of 3DP Process
Excess
Powder
6
Description of 3DP Process
Print Binder
7
Description of 3DP Process
Finished
Part
8
Description from Tim Anderson,
one of Z Corp’s founders
3DP Development and Products
• The technology was developed and patented
by Professor Ely Sachs at MIT, where work
continues on a range of applications
• More about Professor Sachs’ work can be
found at http://web.mit.edu/tdp/www/
• This technology has been sublicensed to a
range of applications in the manufacturing
and medical fields
Z Corporation
• History
– Founded in 1994 by part of MIT’s technical team
– Over 600 customers worldwide
• Products
– Z®400 3D Printer
• Launch: 1998
– Z406 3D Color Printer
• Launch: 2001
– Z810 Large Format 3D Printer
• Launch: April 2002
Z400 3D Printer
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Fast
Versatile
Simple
Affordable- $33,500
Z406 3D Color Printer
• World’s Fastest 3D
Printer
• World’s Only Full
Color Capability
– FEA
– Clear Communication
– Feedback from
Customers
Z406 3D Color Printer
FEA Study
Biomodeling
Communication
Z810 Large Format 3D Printer
• Large build
– 20x24x16 inches
– 500x600x400mm
• Fast
– Cylinder Head in
9 hours
• Versatile
A Variety of Applications
• Functional Test Parts
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Fan blades
Blower wheels
Grill face plates
Plastic housings
• Multiple Tests
• Wind Tunnel
• Calorimeter
• Life Cycle
Z810 Large Format 3D Printer
*RPC EDIT*
You can download this video 167mb video at
http://www.rpc.msoe.edu/members/meetings/2002
/06-21-02/Z810Ovierview.mpg
Competitive Advantage
• Unique capability
– Color
– ZCast
• Speed
– We hold a 2-8X speed advantage
• Cost
– Our materials costs are significantly lower
• Size
– Our 500x600x400 build volume can handle a broad
range of parts
Introductions
APRIL 22, 2002
Griffin Industries
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Single source responsibility
Engineering / Tool Design
Foundry Tooling (prototype and production)
Hog-out Machining
Bridge Tooling
Provide castings – multiple sources
Casting Machining
Resources
Equipment:
• 2 Mori Seiki GV 503
(vertical)
• 2 Mori Seiki SV 500
(vertical)
• 2 Fadal VMC 20 x 40
• 1 Fadal VMC 30 x 60
• 1 24x24x16 Sentry CMM
• 1 24x24x16 Brown &
Sharp CMM
Software:
• 2 Seats of Pro-E
• 7 Seats of Surfcam
• 1 Seat of AutoCAD
• 1 Seat of CAMX
• 1 Seat of Weber Synergy
• Model / Wood Shop…
• Metal Shop…
ZCast Direct Metal Casting
• The ZCast Process is a combination of equipment
and materials developed and manufactured by Z
Corporation
• Owners of Z Corporation’s Z406 or Z810 3D
Printers print a mold or a set of mold inserts, for
direct casting of metal
• The first ZCast material is a plaster/ceramic
composite for use with aluminum and other nonferrous metals
Two Casting Methods
• Direct Pour
• Shell Method
Direct Pour
• Entire mold set
including gating and
vents printed on Z
Corp. printer
• Allows a simpler
design
Shell Method
• Print only shells to
incorporate into a
standard sand casting
mold
• More appropriate for
larger parts
• The two approaches
require different data
preparation
Data Preparation (Shell)
• From the 3D CAD design, create a shell of
uniform ½ inch (1.25 cm) thickness
enclosing the volume of the part
• Select cutting planes or place portals to
facilitate removal of unprinted powder from
inside of mold
• As long as the enclosed powder can be
removed, any geometry is possible
Data Preparation (Direct Pour)
• From STL file, add finish stock to flanges and
mating pieces
• Adding gating and runners using standard industry
practices
• Divide out cores if necessary
• Create mold blocks and then subtract out the
positive, gates and runners
• Add alignment pins and holes if necessary along
the parting surface
• Model in vents if necessary
Print and Prepare Molds
• Print the mold inserts
or molds on the Z406
or Z810 Printer
• Remove the parts from
powder and dry for
several hours to
remove all moisture.
No further infiltration
is required.
Close Mold and Pour Metal
• Current Material set
is a plaster/ceramic
composite for use
with non-ferrous
metals
• Testing to date has
validated Al, Mg, Zn
Remove ZCast Material
Applications and Advantage
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Need for Speed
Reduce Prototype Tooling Cost
Designing Outside the Box
Replacement Parts
Specialty Parts – Alloys –
Mold and core box design
Pattern and core box production
Make molds and
Pour metal
Finish machine
Conventional quick-turn
Sand casting process
5
10
15
20
Days
Mold and core design
ZCast Process
Print Molds
and Cores
Dry molds
Pour Metal
Finish machine
1
2
3
4
Days
Conventional quickturn sand casting
ZCast Process
2 weeks
5
10
15
20
Days
Production Costs
Cost Benefit
Standard processe
ZC
T
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A
s
Elimination of expensive
Up-front tooling costs
Quantity of Same Castings
Performance Factors
• Minimum wall thickness
– 3mm
• Accuracy
– +/-0.015” (0.38mm)
• Surface Finish
– 200-300 microns untreated, 100 with mold wash
• Minimum Core Size
– 3.5-4mm
Performance Factors
Cold
Tensile
Strength
Silica Sand 120*
Zircon Sand 120*
Silica
Sand*
ZCast 500
285 psi
468 psi
280 psi
285 psi
Major Automotive Company
• Wednesday:
– Learned that they needed a part for functional
test and their existing SLA part would not do
– Emailed their part data to Griffin
• Thursday: Mold created and printed
• Friday: Metal poured
• Monday: Parts delivered.
Plumbing Supply Company
• Monday:
– Learned that they needed a new spigot design
for test in one week
– Sent part data to Griffin
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Tuesday: Mold and core data created
Wednesday: Part printed
Thursday: Metal poured
Monday: Parts delivered.
Development Objectives
– Broader Range of Metals
– Improved Performance Characteristics
Mold set with core
Al casting
Part
Dimensions
Mold Print Time
Part
Dimensions
Mold Print Time
Valve Body
33 x 24 x 12cm
8.3 x 6 x 3 inches
3 Hours 58 Minutes
Small Manifold
28.3 x 17.5 x 10cm
7.1 x 4.4 x 2.5 inches
3 Hours 32 Minutes
Part
Dimensions
Mold Print Time
Part
Worm Gear
5.8 x 4.8 x 4.5 inches
23 x 19 x 18cm
6 Hours 30 Minutes
Pump Housing
14 x 9.25 x 7.75 inches
Dimensions
36 x 23 x 20cm
Mold Print Time 20 Hours 50 Minutes