Mold Pattern Research Articles

Application of symbolic language and pattern innovation of Chaoshan peach cake mold in paper packaging design

To explore the symbolic language of the Chaoshan peach cake mold and its innovative applications in modern design, the material form and cultural connotations of the mold patterns were analyzed from a semiotic perspective. Through a symbolic language of the primary pattern elements, the essence of the traditional culture they embody was revealed. Building on this analysis, the generative rules of shape grammar were applied to creatively reinterpret and recombine these traditional pattern elements, resulting in a set of innovative designs that retain the essence of traditional culture while incorporating modern design aesthetics. Furthermore, these innovative patterns were implemented in paper packaging design, and their effectiveness was validated through product evaluation. Through an in-depth exploration and innovative application of the symbolic language of the Chaoshan peach cake mold, a successful fusion of traditional cultural symbols and contemporary design concepts was achieved. This approach provides a new pathway for the inheritance and innovation of Chaoshan peach cake mold culture and offers insights into the modern transformation of other traditional cultures.

Digital Manufacturing System of Custom Wigs with Measurable 3D Images

Wigs are major important means for improving life quality of the increasing people suffered from hair loss through their image enhancements. For the production of custom made wigs, there requires a mold that reproduces the wearer’s head dimension and the shape of hair loss. The conventional method for this is to make a resin film that adheres to the wig wearer’s head using vinyl tape, and to make a wig pattern with drawing the shape of hair loss onto the film, and to produce a head mold with this pattern, and then to plant hair in a wig cap made based on this mold and wig pattern. This method requires highly skilled manual work, and generates a large amount of chemical waste during the manufacturing process, and takes a long manufacturing period. However, the digital automation of measuring head dimension and the shape of hair loss can replace or omit the production of wig patterns. In this study, a 3D head image capable of actual measurement was implemented by using a 3D polygon head shape measurement device and a camera, which makes a digital production system possible, which can replace the manual wig pattern production process for custom wigs.

Research on preparation of micron-scale orthogonally aligned HMS patterns based on soft lithography

The soft lithography enables the fabrication of microfluidic honeycombs, which are micron-scale, orthogonally aligned hexagonal mesoporous silica (HMS) patterns with channels embedded within them, on silicon substrates. The process entails meticulous cleaning, precise master mold design (including features for channel alignment) using electron-beam lithography, generation of polydimethylsiloxane (PDMS) mold creation, ink formulation, and pattern transfer. Subsequent steps include the sol-gel transition, hardening, alignment verification, characterization, and optional functionalization. It is of the utmost importance to optimize these steps and the master design in order to achieve success. Therefore, the paper examines the creation of micron-scale HMS patterns with orthogonal alignment through the innovative application of soft lithography. The technique encompasses the strategic design of hexagonal motifs, precision master mold crafting, the PDMS stamps, and a meticulous sol-gel procedure, resulting in HMS structures that exhibit remarkable precision and adaptability. This paper underscores the transformative potential of soft lithography in the realm of advanced materials, which offers a controlled and uniform approach to size and uniformity. The refined soft lithography process not only achieves the precise orthogonal alignment of HMS patterns but also highlights its adaptability and economic viability in nanotechnology ventures.

Continuous casting process based on an optimized submerged entry nozzle

Continuous casting process is an important part in the steel manufacturing process. The slab production quality is commonly influenced by mould and flow pattern of submerged entry nozzles (SEN). Hence, the present work aimed to attain a more liquid flow rate to increase the slab production quantity within a certain period. Moreover, a novel African Buffalo Algorithm (ABA) is presented in this work to optimise the SEN parameters and the SEN was designed in the MATLAB environment. The developed ABA model optimises the design parameters of SEN such as the size of the nozzle, the shape of the port, length, submergence depth, etc. The fitness of buffalo effectively optimises the SEN parameters and by utilising the optimised design parameters, the SEN was resigned in the MATLAB to identify the proposed framework's effectiveness. The results demonstrated that the liquid flow rate is increased and surface tension gets minimised. When the flow rate of liquid grows, the wave amplitude also upturns. The effect of liquid and air flow rate, port shape and size, maximum wave amplitude, surface tension, etc., were calculated with 0° parallel port. In addition, the presented SEN's results were compared with other existing SEN to determine the optimised SEN's effectiveness. The comparison result demonstrated that the designed optimised SEN has a high liquid flow rate, casting speed, density and viscosity.

Characterization and Detection Classification of Moldy Corn Kernels Based on X-CT and Deep Learning

Moldy corn produces aflatoxin and gibberellin, which can have adverse effects on human health if consumed. Mold is a significant factor that affects the safe storage of corn. If not detected and controlled in a timely manner, it will result in substantial food losses. Understanding the infection patterns of mold on corn kernels and the changing characteristics of the internal structure of corn kernels after infection is crucial for guiding innovation and optimizing detection methods for moldy corn. This knowledge also helps maintain corn storage and ensure food safety. This study was based on X-ray tomography technology to non-destructively detect changes in the structural characteristics of moldy corn kernels. It used image processing technology and model reconstruction algorithms to obtain the 3D model of the embryo, pores and cracks, endosperm and seed coat, and kernels of moldy corn kernels; qualitative analysis of the characteristic changes of two-dimensional slice grayscale images and 3D models of moldy corn kernels; and quantitative analysis of changes in the volume parameters of corn kernels, embryos, endosperm, and seed coats as a whole. It explored the detection method of moldy corn kernels based on a combination of X-ray tomography technology and deep learning algorithms. The analysis concluded that mold infection in maize begins in the embryo and gradually spreads and that mold damage to the tissue structure of maize kernels is irregular in nature. The overall volume parameter changes of corn kernels, embryos, endosperm, and seed coats in the four stages of 0 d, 5 d, 10 d, and 15 d showed a trend of first increasing and then decreasing. The ResNet50 model was enhanced for detecting mold on maize kernels, achieving an accuracy of over 93% in identifying mold features in sliced images of maize kernels. This advancement enabled the non-destructive detection and classification of the degree of mold in maize kernel samples. This article studies the characterization of the characteristic changes of moldy corn kernels and the detection of mildew, which will provide certain help for optimizing the monitoring of corn kernel mildew and the development of rapid detection equipment.

Investment Casting Simulation of ASTM F75 Acetabular Implant with Mold Pattern Orientation and Gating System Geometry Variation

An acetabular implant is a cup-shaped implant that wraps around the head of the femur at the hip joint. Severe damage to the acetabular implant results in bone turnover. To meet the needs of implants, appropriate implant manufacturing techniques are needed. Investment casting is the most widely used casting method because it has the best dimensional accuracy. To help reduce production costs in the industry, this research was carried out using the ProCast 2018 Software. In this study using the 2018 ProCast Software with investment casting techniques with CoCrMo material and variations in the orientation of the mold pattern, namely 0o, 45o, 90o and variations in the shape of the sprue including straight sprue , tapper sprue, and reverse tapper sprue. From these variations, the most optimal result is the tapper sppue variation with 0o print pattern orientation. With the results of the analysis related to the temperature distribution that occurs, fluidity, solidification process and the most optimal shrinkage porosity.

Miniature Fuel Cell with Monolithically Fabricated Si Electrodes- Application of a PDMS Flow Channel for Operando Observation -

Miniature fuel cells have attracted attention as an ultimate portable power source, and we have developed monolithically fabricated Si electrodes for the miniature fuel cells [1,2]. In the fuel cells, two Si electrodes with porous Pt catalyst layer are pressed onto either side of a PEM (polymer electrolyte membrane) , and the prototype fuel cells showed promising performances of over 500mW/cm2 output at 313K with H2-O2. However, the high output was obtained with only small reaction area. Along with enhancement of the reaction area, the performance dropped. We assumed that the performance drop is caused by flooding due to increased water production, which was ignored because MEMS fuel cells are dimensionally small and the outputs are also small. In this study, we attempted to observe the behavior of produced water on the fuel flow channel using a novel transparent channel cover as shown in figure 1. Furthermore, it was assumed that the produced water stays in the concave portions on the catalyst layer, and stripe-shaped projections were formed on the channel cover to prompt drainage of the produced water from the fuel channels.The transparent fuel channel cover was fabricated with PDMS using soft lithography techniques. Initially, a mold for the cover was made with a dry film resist. Micro stripe pattern with 40μm width were made. Considering the PDMS shrinkage during polymerization, the mold pattern had to be formed a few percent larger than the desired shape. Figure 2 shows the whole view of the PDMS channel cover on a miniature fuel cell with Si electrodes. The reaction on the Si substrate was 1mm and 4mm long. Within the area, 100μm x 100μm sections were etched down to the backside catalyst layer. Magnified view on the reaction area is shown in figure 3. It was found that the stripes were finely aligned on the concave portions on the Si electrode.Figure 4 shows the polarization curves of the power generation tests. Results with the novel fuel channel cover with stripes showed higher output compared to the conventional simple cuboid straight shape cover. Figure 5 shows the microscopic view of the channel. While produce water droplets were observed on downstream area in the conventional cuboid shape channel, no droplets were observed with the novel channel cover. It was assumed that drainage of the produced water was successfully prompted and smooth fuel supply to the catalyst layer was realized by the novel fuel channel cover. Acknowledgement This work was partly performed under the Cooperative Research Program of “NJRC Mater. &Dev.” References [1] M. Kobayashi, T. Suzuki, M. Hayase, Journal of Power Sources, 267, 622-628 (2014).[2] R. Shirai, et al., Journal of The Electrochemical Society, 166(15), D834 (2019) Figure 1

One-Step Fabrication Bioinspired Flexible Hierarchical Micro-Nano Structures with Different Morphologies.

In this study, different flexible structures that are morphologically like the micro-nano pillars, setae, and cilia on many natural organism surfaces are created with a novel fabricating strategy to explore the phenomenon and mechanism of static and dynamic droplets forming on them. Just by adjusting the mold pattern during fabrication, different micro/nanomorphologies including micro-nano pillar, filament, or flake arrays could be conveniently obtained on a pristine smooth film surface. Due to the existence of uniformly distributed hierarchical micro-nano structure arrays that are composed of top-down nanoscale filamentous tips, micro block bases, and grooves on the film, air trapped in arrays connects the atmosphere continuously and forms a successive air-pocket layer, which greatly reduces the solid-liquid interfacial fraction and endows the micro-nanotextured film with the capability of superhydrophobicity, low-adhesion, self-cleaning, anti-icing, and deicing characteristics. Through various mechanical and chemical tests, the film has demonstrated its robustness, making it highly suitable for a wide range of practical engineering applications.

Influence of doping MnCl2 in Ce, Fe and Al lattice on its oxygen storage capacity to use as a synthesis catalyst for reducing emission in IC engine

A series of MnCl2 catalysts were synthesised in order to study the Ce/Al/Fe ratios and Ce/Al/Fe catalyst as an external effect of morphological support to reduce NO (nitrogen oxide) emission with NH3 while working at low temperatures. When compared to other low-temperature catalysts, the NOx conversion result is also high. The Ce/Al/Fe ratio was 1:1:1 above the MnCl2 catalyst, indicating that the surface acidity is high and that the NH3 side reaction was inhibited. Mould catalysts are commonly used in selective catalytic reduction (SCR) reactions because they contain Ce/Al species and have a high oxygen content. The hydrothermal method utilised to make the catalyst in a mould pattern improved the NOx conversion efficiency. During the Quick SCR reaction technique, MnCl2 oxygen levels increased while NO emissions decreased. The NO emission is reduced by almost 26.28% and the other emissions, such as HC and smoke, are reduced by around 4.34% and 15.62%, respectively, compared to HTSO100 and compare to diesel, NO emission reduced around 34.5% whereas other emission like HC and smoke reduced around 8.33% and 16.92%, respectively, which is due to the addition of an MnCl2 + CeCl2 +FeCl2 + AlCl2 in the exhaust without affecting brake thermal efficiency.

ANALISIS PENGENDALIAN KUALITAS PRODUK GIBOULT MENGGUNAKAN METODE NEW SEVEN TOOLS DI PT ANEKA ADHILOGAM KARYA

ABSTRACT
 
 PT Aneka Adhilogam Karya is a company located on Jl. header Batur Jaya, Batur, Tegalrejo, Kec. Ceper, Kab. Klaten, Central Java 57465. The company is a metal casting industry manufacturing/manufacturing, specifically a manufacturer of pipe connection equipment for drinking water/pressurized similar fluids and a manufacturer of drainage system components. One of them is the Gibol product, the problem with this company is that there are still a large number of defective and rejected products during the production process. Based on data obtained from PT Aneka Adhilogam Karya, it shows that there are many product defects that occur, to be precise in 2022 with a total number of repairs of 121 defective products, namely in the kropos category, total defects 20, percentage of defects 16.53%, continuous total defects 34, percentage of total defects. defect 28.10%, incomplete defect 41 percentage of total defects 33.90%, total defect table 26 percentage of total defects 21.50%. With product defects that occur, quality control is needed, namely by using the New Seven Tools method. By using 7 (Seven) data processing steps including Affinity Diagrams, Ship Relationship Diagrams, Tree Diagrams, Matrix Diagrams, Matrix Data Analysis, Arrow Diagrams, and Process Decision Program Charts. Get some problems, namely in the category of human factors the operator does not work according to the SOP, the operator is negligent, lack of communication. The method categories are mold pattern design, metal material composition, smelting process, pouring process, inlet and riser channel arrangement. The environmental categories are flying dust, the noisy work area reaches 98 dB with a noise standard of 85 dB, the hot work area reaches 31°C - 35°C. The engine category is the occurrence of problems with the smelting machine, lack of machine maintenance. By doing data processing to get control results, namely by setting up machines, improving the performance of human resources and methods, improving the environment, maintaining machines, replacing tools with new ones, conducting operator training, adding blowers.
 Keryword: Product Defects, Gibol, Quality, New Seven Tools

PENGARUH TEMPERATUR CETAKAN TERHADAP STRUKTUR MIKRO DAN KEKERASAN PISTON HASIL PENGECORAN MENGGUNAKAN 3D PRINTING

Motorcycle users in 2019 reached 133,617,012 units in Indonesia. The impact of a large number of motorcycle certainly attracts the interest of the industry to produce two-wheeled automotive vehicles. The piston is part of the engine that functions as a compression barrier in the combustion chamber, the piston material is aluminum alloy. Therefore, research was carried out on making pistons with investment casting methods, physical and mechanical patterns from 3D printers on pistons. This research starts from drawing the piston using CAD (computer-aided design), making a printed pattern from a 3D Printer machine with PLA (polylactide acid) material. The mold pattern is coated with a mixture of gypsum cement and silica powder. The casting process with a pouring temperature of 750ᵒC and a mold temperature of 200 ᵒC, 250 ᵒC, 300 ᵒC, 350 ᵒC, and 400 ᵒC. The results showed the largest grain size at a mold temperature of 400ᵒC. The highest hardness at 200 ᵒC mold temperature is 47.00 HRB and the lowest hardness at 400 ᵒC mold temperature is 40.56 HRB. The higher the temperature of the mold used, the level of porosity of a material will decrease. This is due to the temperature difference when pouring the molten metal and the lower mold temperature. This makes the metal solidification time longer. The higher the mold temperature, the slower the solidification time, the larger the grain structure, and the decreased hardness.

Pengaruh variasi laju aliran dan preheating cetakan pada investment casting terhadap sifat fisis dan mekanis prototipe aluminium cylinder head engine

This research studies the effect of flow rate on the pouring of molten metal into the mould so that the flow rate into the mould can be controlled. Furthermore, this research studies the effect of mould preheating so that the temperature inside the cavity can be maintained, especially for narrow holes. The process starts with making the engine cylinder head pattern and gating system using a three-dimensional printer with polylactic acid resin. The mould pattern and gating system are combined and coated with a layer of cement plaster, silica sand and kaolin. After the coating is dry, the mould is heated until the mould pattern evaporates and there is no residue. The casting process was carried out at pre-heating moulds of 300 0C and 350 0C and a pouring temperature of 800 0C with pouring speeds of 20, 30, and 40 rpm. The final stage of the research is manufacturing test objects and testing mechanical properties. The results showed that the higher the pouring speed, the less perfect the casting results, especially in the cylinder head fins. The best casting results occurred in the pre-heat condition of the 300 0C mould with a pouring speed of 20 rpm, with a Maximum Tensile Strength of 105 N/mm2, Hardness 53 hardness Brinell test (HBN), Density and Porosity of 2.43 gr/cm3. The material used in this study refers to the reference is A356 Aluminum Alloy.

A sustainable formwork system based on ice pattern and sand mould for fabricating customised concrete components

PurposeOptimised concrete components are often of complex geometries, which are difficult and costly to cast using traditional formworks. This paper aims to propose an innovative formwork system for optimised concrete casting, which is eco-friendly, recyclable and economical.Design/methodology/approachIn the proposed formwork system, ice is used as mould pattern to create desired geometry for concrete member, then sand mould is fabricated based on the ice pattern. A mix design and a mixing procedure for the proposed sand mould are developed, and compression tests are also performed to ensure sufficient strength of the sand mould. Furthermore, surface preparation of the sand mould is investigated for easy demoulding and for achieving good concrete surface quality. Additionally, recyclability of the proposed sand mould is tested.FindingsThe proposed mix design and mixing procedure can provide sufficient strength for sand mould in concrete casting. The finished components exhibit smooth surfaces and match designed geometries, and the proposed sand mould can be fully recycled with satisfactory strength.Originality/valueTo the best of the authors’ knowledge, this is the first study that combines ice pattern and sand mould to create recyclable formwork system for concrete casting. The new techniques developed in this research has great potential to be applied in the fabrication of large-scale concrete structures with complex geometries.

Low Cost, Ease-of-Access Fabrication of Microfluidic Devices Using Wet Paper Molds.

Rapid prototyping methods enable the widespread adoption of microfluidic technologies by empowering end-users from non-engineering disciplines to make devices using processes that are rapid, simple and inexpensive. In this work, we developed a liquid molding technique to create silicone/PDMS microfluidic devices by replica molding. To construct a liquid mold, we use inexpensive adhesive-backed paper, an acetate backing sheet, and an off-the-shelf digital cutter to create paper molds, which we then wet with predetermined amounts of water. Due to the immiscibility of water and PDMS, mold patterns can be effectively transferred onto PDMS similarly to solid molds. We demonstrate the feasibility of these wet paper molds for the fabrication of PDMS microfluidic devices and assess the influence of various process parameters on device yield and quality. This method possesses some distinct benefits compared to conventional techniques such as photolithography and 3D printing. First, we demonstrate that the shape of a channel’s cross-section may be altered from rectangular to semicircular by merely modifying the wetting parameters. Second, we illustrate how electrical impedance can be utilized as a marker for inspecting mold quality and identifying defects in a non-invasive manner without using visual tools such as microscopes or cameras. As a proof-of-concept device, we created a microfluidic T-junction droplet generator to produce water droplets in mineral oil ranging in size from 1.2 µL to 75 µL. We feel that this technology is an excellent addition to the microfluidic rapid prototyping toolbox and will find several applications in biological research.

Structural Design for Improving the Strength of Flat Wooden Pallets

The purpose of this study is to develop a new pallet structure using the inexpensive hinoki wood, which is produced in the Ehime Prefecture, having the same strength as the conventional Oregon pine wood. A new pallet structure was proposed for achieving high-strength by improving the flexural stiffness and compressive stiffness and achieving high-cost performance by using the inexpensive hinoki wood. The results obtained in this study are summarized as follows: deflection of the new type is reduced compared to the standard type, due to the increased bending rigidity of the edge board and deck board; compressive displacement of the new model decreases, as the compressive stiffness of the pallet legs increases; new mold pattern 6 made is higher in strength and rigidity than the standard mold; cost of the new type #6 is 72% of that of the standard type pallet, and cost can be reduced by 28%.

Additive manufacturing integrated Casting- A review

Integration of advanced manufacturing technology with traditional methods is a need for the current situation. Additive manufacturing technology is the most advanced manufacturing technology adopted by various industries. Foundry industries share a big percentage among the other manufacturing industries and are also capable to manufacture parts with complex geometry which are otherwise not possible or very difficult to produce with other manufacturing processes. Integration of additive manufacturing technology with the casting process can bring a new evolution in the foundry industry. The traditional casting process involves several complex and time-consuming steps, along with costly tooling. To make mold or core or pattern for small production is not an economical task. In this study casting manufactured by Additive manufacturing integrated casting is compared with conventional cast and comparison has been done based on dimensional accuracy, strength, time, surface roughness, and amount of material used. The main focus has been given to investment casting and sand mold casting as they are widely used for the production of cast parts. Moreover, challenges/limitations, current trends and future scope in additive manufacturing integrated casting have been discussed. This study helps the researcher to find a novel methodology to improve the capability of additive manufacturing integrated casting for various applications in the 21st century.

Nanoimprinted and Anodized Templates for Large-Scale and Low-Cost Nanopatterning.

Nanopatterning to fabricate advanced nanostructured materials is a widely employed technology in a broad spectrum of applications going from spintronics and nanoelectronics to nanophotonics. This work reports on an easy route for nanopatterning making use of ordered porous templates with geometries ranging from straight lines to square, triangular or rhombohedral lattices, to be employed for the designed growth of sputtered materials with engineered properties. The procedure is based on large-scale nanoimprinting using patterned low-cost commercial disks, as 1-D grating stamps, followed by a single electrochemical process that allows one to obtain 1-D ordered porous anodic templates. Multiple imprinting steps at different angles enable more complex 2-D patterned templates. Subsequently, sputtering facilitates the growth of ferromagnetic antidot thin films (e.g., from 20 to 100 nm Co thick layers) with designed symmetries. This technique constitutes a non-expensive method for massive mold production and pattern generation avoiding standard lithographical techniques. In addition, it overcomes current challenges of the two-stage electrochemical porous anodic alumina templates: (i) allowing the patterning of large areas with high ordering and/or complex antidot geometries, and (ii) being less-time consuming.

Ideally Ordered Anodic Porous Alumina on Si Substrate Prepared by Anodization of Sputtered Al–Mg Thin Film

Anodic porous alumina with an ideally ordered hole arrangement was formed on a Si substrate by nanoimprinting and subsequent anodization. In this process, the arrayed shallow dimples formed by nanoimprinting using a mold act as initiation sites of hole development during the anodization. To realize the precise transfer of the mold patterns to the Al surface during nanoimprinting, we used sputtered Al alloy film as a starting material. This is because the Al alloy with appropriate impurities as a sputtering target can suppress the crystal grain growth during sputtering and allow the formation of Al alloy films with smooth surfaces on the substrate. Dimple arrays with 100 nm intervals could be formed on the flat surface of the Al–Mg film on the Si substrate. Ideally ordered anodic porous alumina with an interpore distance of 100 nm was successfully obtained by subsequent anodization. A Co/alumina composite was also obtained by the electrodeposition of Co into the alumina holes. The obtained samples are expected to be applied to various functional devices requiring an ideally ordered structure on a substrate.

Automated Filling of Dry Micron-Sized Particles into Micro Mold Pattern within Planar Substrates for the Fabrication of Powder-Based 3D Microstructures.

Powder-based techniques are gaining increasing interest for the fabrication of microstructures on planar substrates. A typical approach comprises the filling of a mold pattern with micron-sized particles of the desired material, and their fixation there. Commonly powder-loaded pastes or inks are filled into the molds. To meet the smallest dimensions and highest filling factors, the utilization of dry powder as the raw material is more beneficial. However, an appropriate automated technique for filling a micro mold pattern with dry micron-sized particles is missing up to now. This paper presents a corresponding approach based on the superimposition of high- and low-frequency oscillations for particle mobilization. Rubber balls are utilized to achieve dense packing. For verification, micromagnets are created from 5 µm NdFeB powder on 8” Si substrates, using the novel automated mold filling technique, as well as an existing manual one. Subsequent atomic layer deposition is utilized to agglomerate the loose NdFeB particles into rigid microstructures. The magnetic properties and inner structure of the NdFeB micromagnets are investigated. It is shown that the novel automated technique outperforms the manual one in major terms.

Effects of sand and gating architecture on the performance of foot valve lever casting components used in pump industries

This work addresses manufacture, testing and simulation of foot valve lever (FVL) for monoblock pump industry, using a cost-effective casting design process. The impact of different types of sands, such as air-set, dry and sodium silicate as well as gating designs, namely H-, U- and O-type, were studied with respect to surface roughness and porosity. The mold pattern was produced using additive manufacturing (AM) technology. Both experimental and numerical investigations were performed on the temperature distribution of molten metal at random locations for the different gating configurations or designs, considering mold filling and solidification. It was evident from the experimental investigation that contribution of air-set sand and O-type gating architecture showed limited consistency effects. Importantly, gating architecture was the most influential parameter to determine all specified quality outcomes, independent of sand mold. An order of O < H < U-type was obtained from the gating designs for minimal surface roughness and percentage of porosity. Furthermore, the microstructure analysis depicted only an irregular defect with minimum quantity at both surface and cross-section of O-type at two different locations. Optimum pouring temperatures of 740, 750 and 790 °C were obtained for mold filling of all 24 components of H-, O- and U-type of gating designs, respectively. The varying solidification temperature was observed from real time thermocouple reading, which was in close agreement with the numerical simulation. Evidently, O-type of gating design exhibited best performance for large-scale development of the FVL in terms of surface roughness, porosity and cooling effects.