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Cited by 73Additive Manufacturing and 3D Printing TechnologiesTopology Optimization in EngineeringAdditive Manufacturing Materials and Processes

Design and Topology Optimization of 3D-Printed Wax Patterns for Rapid Investment Casting

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Wang, Jiayi, Sama, Santosh Reddy, Lynch, Paul C., Manogharan, Guha·2019·Procedia Manufacturing
DOI 10.1016/j.promfg.2019.06.224
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Abstract

Traditional investment casting (IC), also known as lost-wax casting, suffers from high tooling cost and long lead-time during fabrication of wax patterns. In recent years, rapid investment casting (RIC) based on AM has become widely accepted in casting foundries due to rapid production of patterns without any tooling requirements. Direct AM production of wax patterns is not only cost-efficient for low volume production but also capable of creating freeform and highly complex geometries that are otherwise extremely difficult or too expensive to cast conventionally. Such advantages provide unlimited opportunities in the cast part design and enable the use of advanced design tools especially advanced optimization tools like topology optimization (TO). In this study, knowledge-based design guidelines for rapid investment casting are developed through streamlined integration of TO with design for investment casting and design for AM principles. Specifically, TO routine based on Solid Isotropic Material with Penalization (SIMP) method using Abaqus Topology Optimization Module (ATOM) has been developed for both material extrusion and investment casting constraints. Part design optimization is demonstrated for this new technique and is validated by a case study using heat-treated ASTM A216 WCB cast carbon steel parts. AM patterns for investment casting are produced using commercially available wax filaments. Wax material extrusion parameters are identified for optimal AM accuracy and surface finish.

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  • Processes like SLS reduce production costs, with lead times of approximately two weeks compared to 40-50 weeks for traditional methods.

    “Additionally, processes like SLS reduce production costs, with lead times of approximately two weeks compared to 40-50 weeks for traditional methods [135].”

    From Towards Sustainability in Hydraulic Machinery Manufacturing by 3D Printing (2024) · cites this paper as [135]

    The Conclusions (page not provided) report lower cost for a low-volume investment-casting case study and a lead time of less than two weeks for fabricating 3D-printed wax-like patterns, versus 40–50 weeks to design and fabricate traditional pattern dies. But the study used material extrusion, not SLS, so it does not establish those cost and lead-time figures for SLS. (LLM, conf=0.89)

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Research works printed but not linked: 31

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Sorted by citations

Authors
Wang, J., Sama, S. R., Lynch, P. C., & Manogharan, G.
Affiliations
Pennsylvania State University (US)
Corresponding author
Manogharan, Guha
ORCID
Venue
Procedia Manufacturing
Publisher
Elsevier BV
Published
2019
Volume
34
Pages
683-694
ISSN
2351-9789 (ISSN-L)
DOI
10.1016/j.promfg.2019.06.224
OpenAlex
W2963576526
Cited by
73
References
0
Citations by year
2026: 4 · 2025: 10 · 2024: 8 · 2023: 13 · 2022: 17 · 2021: 10 · 2020: 11
FWCI
4.34
Type
journal article
Language
en
Open access
Licence
Locations
Procedia Manufacturing (publishedVersion, cc-by-nc-nd)
Topics
  • Physical Sciences › Engineering › Automotive Engineering › Additive Manufacturing and 3D Printing Technologies
  • Physical Sciences › Engineering › Civil and Structural Engineering › Topology Optimization in Engineering
  • Physical Sciences › Engineering › Mechanical Engineering › Additive Manufacturing Materials and Processes
Keywords
investment casting, wax patterns, 3D printing, topology optimization, SIMP method, additive manufacturing, design for additive manufacturing, material extrusion, wax filaments, part design optimization

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