Novel use of robotic 3D paste printing technology for the creation of ceramic shell investment casting moulds

Bolouri, Amir; Jorgensen, Tavs; Khayatzadeh, Saber; Soe, Shwe; Leon, Marianthi; Lightfoot, Sonny; Joyce-Badea, Michael; Farzadnia, Farzad

Abstract

This paper presentation outlines early-stage, ongoing research into novel approaches with Additive Layer Manufacturing for the direct manufacture of ceramic shell investment casting moulds. The research is focused on the use of 3D printing with refractory mould paste using 6-axis robotic arms. This particular approach is entirely novel in the context of the foundry sector but holds significant industrial impact potential. The process allows for sensors and actuators to be embedded into the moulds during the fabrication stage, which can facilitate the creation of ‘Smart Moulds’ relevant to Industry 4.0 and Digital Twin concepts. The paper will report on the development of the core system which involves the creation of bespoke hardware (including augers, electronics, print heads and paste delivery system) and software (including a 3D printing slicer and robotic controller) solutions. The paper will outline challenges of developing a digitally driven ceramic shell paste delivery system, delivering co-ordinated volumes of paste to a bespoke auger based printhead. Key achievements presented is the integration of accurate paste deposition with the movements of the 6-axis robotic arm through the development of bespoke software. Early investment trials with moulds produced with this system will also be presented.

• Presentation Conference Type: Keynote
• Start Date: Jun 7, 2023
• End Date: Jul 10, 2023
• Deposit Date: Jul 27, 2023
• Public URL: https://uwe-repository.worktribe.com/output/10981916