Development of Complex Patterns: Scope and Benefits of Rapid Prototyping in Foundries

Abstract

The quality through frugal engineering concepts has gained prime importance to the foundries around the world. Although simulation packages have been used as a tool to achieve quality and productivity, the use of Rapid Prototyping (RP) is not yet fully practiced in foundries in this concern. This paper provides a detailed study of the fabrication of a complex master pattern (impeller casting) using rapid prototyping technique besides presenting its scope and benefits compared to the current practices. The main objective of this work is to enlighten the foundry engineers to make use of rapid prototyping technology (fused deposition modeling) to eliminate the material wastage in pattern production, reduce the cost and lead-time in the production of accurate complex castings of an acceptable surface quality.