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 MACEDONIAN UNION OF METALLURGISTS

VIIth International Metallurgical Congress,

METALLURGY, MATERIALS AND
ENVIRONMENT
09th – 12st June 2016
Ohrid, Republic of Macedonia

PROCEEDINGS

Edited by:
Sveto Cvetkovski & Goran Načevski
 VIIth International Metallurgical Congress, Ohrid 2016

CONTENTS

Slaviša Moljević, Radoslav Grujić, Ranko Božičković, Ranka Gojković

ANALYSIS OF THE NEED TO IMPROVE QUALITY IN THE MANUFACTURING
INDUSTRY

Radoslav Grujić, Dragan Vujadinović, Kiril Lisichkov, Slaviša Moljević

APPLICATION OF NANOMATERIALS IN FOOD PRODUCTION

Boyan Yordanov, Dimitar Krastev

CHANGES IN THE HARDNESS DEPENDING ON THE HEAT TREATMENT OF
WEAR RESISTANCE CHROMIUM CAST IRON

A.I. Trotsan, G.A. Bagliuk, V.V. Kaverinsky, I.L. Brodetsky

METAL MELTS COMPLEX MODIFYING BY DISPERSE POWDERS

A.I. Trotsan, V.V. Kaverinsky, G.A. Bagliuk, I.L. Brodetsky

ANALYSIS OF STEEL COMPOSITION INFLUENCE ON STARTING AND ENDING
OF  TRANSFORMATION TEMPERATURES USING COMPUTER MODELING

Tsanka Dikova, Dzhendo Dzhendov, Kristina Bliznakova, Danail Ivanov

APLICATION OF 3D PRINTING IN MANUFACTURING OF CAST PATTERNS

Rrahim Maksuti
CHANGES OF MECHANICAL PROPERTIES DURING PRODUCTION OF
LONGITUDINAL SEAM WELDED STEEL PIPES

Dimitar Krastev
ABOUT SOME NONTRADITIONAL PROCESSES FOR SURFACE MODIFICATION
OF STEELS

Tishchenko A.P., Bagliuk G.A., Kolotilo L.N., Spodoba Z.A.

NEW TECHNOLOGIES FOR EXTRACTION OF USEFUL MATERIALS FROM THE
RED MUD

V.P. Kravchenko, G.A. Bagliuk, A.I. Trotsan

MANUFACTURING OF FINE POWDERS WITH ELEVATED BINDING PROPERTIES
AT UTILISATION OF BLAST FURNACE SLAG

Zdravko Božičković, Ranko Božičković, Slaviša Moljević, Darijo Božičković

METHODOLOGY OF THE OPTIMAL DESIGN OF HORIZONTAL HYDRAULIC
PRESS BY SIMULATION TECHNIQUES
 VIIth International Metallurgical Congress, Ohrid 2016

Blagica Cekova, Erhan Mustafa, Filip Jovanovski, Viktorija Bezhovska

METHODS FOR DETERMINING THE INTENSITY OF THE EROSION

Jarmila Trpcevska, Ruzica Manjlovic, Martina Laubertova

BY-PRODUCTS FORMED IN THE HOT DIP GALVANIZING PROCESS

Sulejman Muhamedagić, Ilhan Bušatlić, Selvedin Hrustić

MINERALOGICAL AND PHASE TRANSITIONS IN AGGLOMERATES PRODUCED
FROM LIMONITE ORE, OMARSKA

Miodrag Arsić, Marina Dojčinović, Sveto Cvetkovski, Vencislav Grabulov, Zoran Savić
DAMAGING OF TURBINE RUNNER BLADES THAT OCCURS DUE TO
CAVITATION AT THE HYDRO POWER PLANT „DJERDAP 1“

R. Manojlović, J. Trpcevska, B. Rizov, R. Ilievski, Z. Koneska, D. Stoevska-Gogovska

ACCURACY OF THE SPREAD CALCULATION DURING THE ROLLING OF METAL
MATERIALS

R. Ilievski, R. Manojlović, Z. Martinova, B. Krstevski, Z. Apostolovski

TECHNOLOGICAL PROPERTIES OF THE PROCESSING OF HOT-ROLLED THIN STEEL
PLATES FROM C45 STEEL

Mirjana Golomeova, Afrodita Zendelska, Blagoj Golomeov, Boris Krstev, Shaban Jakupi
REMOVAL OF LEAD IONS FROM ACID AQUEOUS SOLUTIONS USING ZEOLITE
BEARING TUFF

Miroslav Sokić, Branislav Marković, Vladislav Matković, Vaso Manojlović,

Željko Kamberović, Dragana Živković, Nada Štrbac
STRUCTURAL INFLUENCE OF SULPHIDE MINERALS ON THEIR LEACHING
FROM POLYMETALLIC CONCENTRATE BY SODIUM NITRATE IN SULPHURIC
ACID

Laubertová, M., Trpčevská, J., Zórawski, W., Sminčáková, E., Pirošková, J.

SAMPLING PROCEDURE OF PRINTED CIRCUIT BOARDS FROM DISCARDED
MOBILE PHONES

Blagoj Rizov, Ruzica Manojlovic

CHARACTERIZATION OF INTERMETALLIC COMPOUND LAYER AT THE
INTERFACE FORMED DURING SOLID COBALT – LIQUID ALUMINUM CONTACT

Dafinka Stoevska – Gogovska, Zagorka Koneska, Ruzica Manojlovic, Blagoj Rizov,

Jon Magdeski
EFFECT OF TIME AND TEMPERING TEMPERATURES ON PROPERTIES OF
MEDIUM CARBON STEEL

Dafinka Stoevska-Gogovska, Zagorka Koneska, Ruzica Manojlovic, Blagoj Rizov,

Jon Magdeski
INFLUENCE OF TEMPERING TEMPERATURE ON PROPERIES OF C45E

Zagorka Koneska, Dafinka Stoevska – Gogovska, Ruzica Manojlovic

CORROSION BEHAVIOR OF HEAT TREATED MEDIUM CARBON STEEL IN
ACETIC ACID SOLUTINS
VIIth International Metallurgical Congress, Ohrid 2016
VIIth International Metallurgical Congress, Ohrid 2016
VIIth International Metallurgical Congress, Ohrid 2016
 VIIth International Metallurgical Congress, Ohrid 2016

VIIth International Metallurgical Congress,

(Metallurgy, Materials and Environment)
organized by

Macedonian union of metallurgists

under the auspices of the

Ss. Cyril and Methodius University in Skopje

Faculty of Technology and Metallurgy
Economic Chamber of Macedonia
Engineering Institution of Macedonia

General Sponsor
MAKSTIL AD Skopje

The congress organizers gratefully acknowledge the sponsorship of the follow ing companies:
FENI INDUSTRIES Kavadarci, ARCELOR MITTAL Skopje, BUCIM Radovis, JUGOHROM Ferroalloys
Jegunovce, VARDAR Dolomit Gostivar, OGNOOTPORNO Skopje, RZ Institut Skopje, Aleks Skopje,
Tehnicka Kontrola AD Skopje, STEMCOR Skopje, LIPTERM Skopje, Nikov Konsalting Skopje

n.b.: Manuscripts submitted for this Congress were not subjected to language or other
corrections, except in some extreme cases.

Authors are fully responsible for the content of their Abstracts.

CIP - Каталогизација во публикација

Национална и универзитетска библиотека "Св. Климент Охридски", Скопје

669(062)(034.44)
620.1(062)(034.44)
502(062)(034.44)

INTERNATIONAL metallurgical congress (7 ; 2016 ; Ohrid)

Metallurgy, materials and environment [Електронски извор] :
proceedings / VIIth International metallurgical congress,
09.06-12.06. 2016, Ohrid, Macedonia ; edited by Sveto Cvetkovski & Goran Načevski.
- Skopje : Macedonian union of metallurgists, 2016. -
1 оптички диск ЦД-РОМ ; 12 см

Регистар

ISBN 978-9989-9571-8-5

а) Металургија - Собири
б) Испитување на материјалите - Собири
в)Животна средина - Собири

COBISS.MK-ID 101283082
 VIIth International Metallurgical Congress, Ohrid 2016

APPLICATION OF 3D PRINTING IN MANUFACTURING OF CAST PATTERNS

Tsanka Dikova*, Dzhendo Dzhendov*, Kristina Bliznakova**, Danail Ivanov**

*Faculty of Dental Medicine, Medical University of Varna, Varna, Bulgaria

** Technical University of Varna, Varna, Bulgaria
Corresponding author e-mail: tsanka_dikova@abv.bg

Abstract

The aim of the present paper is to review the application of 3D printing technologies for manufacturing of patterns
for investment and sand casting. The additive technologies are characterized with building the object by addition of
the material layer by layer. They offer a number of advantages over the traditional methods: easy, controllable and
relatively quick process; manufacturing of objects with complex geometry; no need of complex tooling equipment;
the desired shape, dimensions and properties can be obtained. The possibilities of stereolithography (SLA), fused
deposition modelling (FDM), multi jet modeling (MJM) and selective laser sintering (SLS) for manufacturing of
polymer patterns for investment and sand casting are discussed. The advantages and the disadvantages of different
printing processes are summarized. The geometrical accuracy and the surface quality of cast patterns, fabricated by
different technologies, are compared. It was observed, that the dimensions of all samples printed within the study
were smaller than that of the virtual 3D models, irrespective of the printer technology used. Concerning the surface
quality - the largest is the surface roughness of the sample created by the FDM printer compared to the SLA and the
MJM printers. The correct choice of the technological parameters of the equipment is important for obtaining 3D
printed cast patterns with high quality and minimum deformations.

Key words: cast patterns, 3D printing, stereolithography, fused deposition modelling

Introduction

The casting processes are widely used in different industrial branches for production of complicated details from
metal alloys, which areis difficult to be manufactured by machining or by forging. In investment and sand casting
the liquid metal is poured into preliminary created mold, while in die casting it is injected into die. Die casting is
used for production of details mainly from Al, Cu and Zn alloys with high accuracy, high surface quality and high
mechanical properties. The machines used are complicated as well as the casting dies are expensive and their
manufacturing is time consuming. Investment casting produces ferrous and non-ferrous metal parts with excellent
surface finish and dimensional accuracy. This manufacturing process is ideal for applications that have relatively
low production quantities or rapidly changing product designs [1]. Since the investment casting uses expendable
patterns and ceramic shells, it is excellent for complex and detailed part designs. Investment casting patterns are
typically injection molded, and when designs are complex, the time and the cost for tools production increases. Sand
casting is a cost-effective, efficient process for small-lot production or high-volume manufacturing when used in
conjunction with automated equipment [2]. The sand casting process is relatively simple; however the fabrication of
patterns to produce the sand molds can be time consuming and labor intensive.
The modern Additive Technologies (AT) offer possibilities to overcome the above mentioned disadvantages.
They are characterized with building of one layer at a time from a powder or liquid that is bonded by means of
melting, fusing or polymerization [3]. Substituting the molded wax patterns in investment casting with patterns,
manufactured by AT, results in both reduced costs and time which incurred with the injection molds [1]. In sand
casting the patterns, matchplate patterns, split patterns, gate and runner systems, core boxes and resin cast patterns
can be manufactured using AT. It can lead to 30%-70% time reduction, 60%-80% average cost savings, possibilities
for redesigns of part/pattern and gate/runner system, optional use of interchangeable components, automated pattern
production [2].
The technologies most suitable for manufacturing of polymeric patterns for casting include stereolithography
(SLA), Fused Deposition Modeling (FDM), Multi Jet Modeling (MJM) and Selective Laser Sintering (SLS) [3,4].
Bassoli E. et al [5] evaluated the dimensional accuracy of two rapid casting solutions based on 3D printing
technology: investment casting starting from 3D‐printed starch patterns and the ZCast process for the production of
cavities for light‐alloys castings. They demonstrated that both rapid casting solutions are effective in obtaining cast
technological prototypes in short times and with low costs, with dimensional tolerances that are completely
consistent with metal casting processes. The research of Ishida Y. and Miyasaka T. [6] has shown that the
geometrical accuracy and surface roughness of dental casting patterns depend on the type of the additive
 VIIth International Metallurgical Congress, Ohrid 2016

manufacturing process. In the most conditions the all samples’ dimensions were smaller than that of the virtual 3D
model. Concerning the deviation from the designed value, the FDM printer showed the best accuracy in terms of
the outer diameter and the worst accuracy in terms of the inner diameter and depth. The MJM and laser SLA printers
showed the best accuracy for the inner diameter and depth. The surface roughness of the sample created by FDM
printer was the largest. The roughness along the tooth axis of the crown created by laser SLA printer was the
smallest and that along the horizontal direction of the crown created by MJM printer was the smallest. Braian M. at
al. [7] determined the production tolerance of polymeric objects produced by four commercially available Additive
Manufacturing (AM) systems using SLS and MJM processes. They showed that the samples’ accuracy depends on
the technological process used as well on the samples’ complexity and sizes. As a whole, the MJM process ensures
the highest overall accuracy of approximately 10 µm for smaller samples (16x16x 7 mm 3) and less than 30 µm for
larger objects (14x44x24 mm3).
The great variety of AT provides different reliability and repeatability of the processes, parts quality,
dimensional accuracy and stability as well as cost effectiveness. Moreover, in recent years new additive
manufacturing processes have been developed. So, the data about their application for production of tooling
equipment for investment and sand casting is relatively scarce. The aim of the present study is to analyze the
possibilities of 3D printing technologies for production of cast patterns.

Additive manufacturing technologies

AM technologies produce parts by polymerization, fusing or sintering of materials in predetermined layers

without need of tools, thus enable production of geometries that are almost impossible to produce using other
machining or molding processes and nearly with no waste. The layers of all AM parts are created by slicing CAD
data with specialized software. Each slice is then printed on the top of the other to create the 3D object – the so
called “3 Dimensional printing” process [3,4,8,9,10]. These processes are also known as “layered manufacturing”,
“freeform fabrication”, “rapid prototyping”, “rapid manufacturing” [11]. The ASTM International committee,
dedicated to the specification of standards for AM, formed in 2009 (known as ASTM F42) created a categorization
of all 3D printing technologies into seven major groups [12].The processes, mostly used for manufacturing of
polymeric details, include stereolithography (SLA), Fused Deposition Modeling (FDM), Multi Jet Modeling (MJM)
and Selective Laser Sintering (SLS) [3,4].
During the SLA process a concentrated beam of UV light is focused onto the surface of a tank filled with liquid
photopolymer and, as the light beam draws the object onto the surface of the liquid, each time a layer of resin is
polymerized or crosslinked (Fig. 1) [3,4,6,10,13]. The light used for the polymerization is either laser beam
controlled by a scanning system or Digital Light Projection (DLP) image. The FDM process is characterized with
extruding of the thermoplastic materials through heated nozzle onto the part surface where it solidifies (Fig. 2)
[3,4,6,10,13]. The MJM process uses piezo print head technology to deposit either photocurable plastic resin or
casting wax materials layer by layer using multiple nano size jets (Fig. 3) [4,6]. In SLS layers of particular powder
material (polymer, ceramic) are fused into a 3D model by adopting a computer-directed laser [3,4,10,13]. The laser
automatically scans the space defined by the 2D slice of a 3D model, binding the material particles together to create
a solid structure [4].
a) c) d)

b) e)

Fig. 1 3D printing process of cast patterns of dental bridges. Generating of virtual 3D model – a), design of
the support structures – b), 3D printer, working on DLP stereolithography process – c) and as-printed cast
patterns – d) and e).
 VIIth International Metallurgical Congress, Ohrid 2016

a) b) c)

Fig. 2 3D printing system, working on the basis of FDM

– a) and patterns for investment casting of dental bridges,
printed in two positions – b) and c).

The AM manufacturing technologies are characterized with many advantages over the traditional production
methods – easy, controllable and relatively quick process; manufacturing of objects with complex geometry; no
need of complex tooling equipment; the desired shape, dimensions and properties can be obtained.

Application of AM for production of cast patterns

The application of 3D printing in the production of cast patterns offers many benefits such as reduced time and
costs for their fabrication, automated pattern production as well as it allows the use of interchangeable components.
In manufacturing of cast patterns by AM the type of the casting process (investment or sand casting) plays
important role. It defines the type, the sizes and the accuracy of the cast patterns as well as the materials, used for
their fabrications. The peculiarities of different AM processes also should be very well known. On that basis, the 3D
printer, most suitable for the given application, has to be chosen.

 Materials for 3D printed patterns

As the investment and sand casting are quite different technological processes, the materials, used for
manufacturing of patterns have to meet different requirements. From the other hand, the companies, producing 3D
printing systems, develop various materials especially intended for these systems. Therefore, the appropriate choice
of the cast pattern material depends on the types of both – the casting and the AM processes.

d)

a)

c)

Fig. 3 3D printing of patterns for investment

casting using MJM process. Virtual 3D model –
b) a), design of the printed area- b), 3D printer – c)
and as-printed pattern – d).
 VIIth International Metallurgical Congress, Ohrid 2016

The materials for investment casting patterns have to possess good burnout characteristics [1] and minimum or
no expansion during burnout process. Otherwise the ceramic shell or the cast mold will be cracked, leading to
casting with low quality. To promote complete removal of the 3D printed patterns and decrease the potential for
shell cracking, the burnout in two steps is recommended – standard de-waxing at first, followed by burnout process
in the furnace pre-heated up to 870oC [1]. The materials for investment casting patterns have to be easier post
processed due to the soluble supports and compatibility with solvent smoothing. The materials, recommended for
manufacturing of lost wax cast patterns by FDM process include polymers from the ABS family - ABS, ABS plus
and ABS-M30 [1].
The patterns for sand casting are used for multiple manufacturing of sand molds. So, the materials for their
production should possess high hardness, high strength and abrasion resistance, but at the same time they have to be
finished easily. The materials most commonly used in FDM manufacturing of sand cast patterns are ABS-M30, PC
and ULTEM™ 9085 [2]. ABS-M30 is the easiest to finish with lowest cost and strength up to 20.7 MPa. The PC is
the most abrasion resistant with strength up to 41.4 MPa. It is a good compromise of strength and cost. The
ULTEM™ 9085 is thermoplastic resin - the strongest material with strength up to 68.9 MPa and naturally
lubricious.
The FDM process (Fig. 2) is not recommended for small, fine-featured items common to jewelry-making or
similar [2]. In that cases the SLA printers are more suitable, because they are among the most accurate ones for
fabrication of 3D objects [10]. Two castable materials are currently optimized by the EnvisionTEC Company for use
on the Perfactory® Micro printer, working on the principle of the DLP stereolithography with LED [14]. The PIC
100 is intended for small, very high detailed parts and EC500 - for larger items and items that are more difficult to
cast. EnvisionTEC also offers HTM140 for high temperature molding. The Rapidshape Company introduced four
resins for casting purposes – CP 201, CP 201+, CP 202+ and NextDent Cast [15]. The first three resins are
especially designed for conventional investment casting process in the jewelry, while the last one is for application
in dentistry.
Currently, there is huge variety of materials used in 3D printing. That is why continuous testing and evaluation
with these materials need to be conducted.

 Special features of 3D printing processes

3D printing systems use different AM processes, affecting the dimensional accuracy, surface roughness and the
overall object quality. For manufacturing of precise cast pattern, guaranteeing casting with high quality, it is
important to know the advantages and disadvantages of different AM processes, the main manufacturing problems
and the ways to avoid them.
Using SLA process details with complex geometry, good accuracy and excellent quality surface can be produced
(Fig. 1e). However, the 3D printed parts need support structures, they can deform easily [4,12] and final photo-
polymerization is needed.
A wide range of polymeric materials can be used in FDM process. The machines are easily adjusted and can be
used in an office environment (Fig. 2a) [4]. The 3D printed objects also need support structures. They possess low
strength in the vertical direction and rough ‘textured’ outer surface (Fig. 2b and Fig. 2c), which can cause problems
in tool manufacturing. The FDM is comparatively slow process [4,10].
The MJM process is relatively fast and it is suitable for an office environment (Fig. 3c) [4]. The strength of the
3D printed details is low, they need support structures and after their removal the traces are left, limiting the usage
for casting models.
In the SLS process high range of materials can be used with no need of supports and further sintering [4]. The
process is time and energy consuming. The surfaces of the objects are rough and porous, which need additional
processing in manufacturing of cast patterns.
o Accuracy
ISO describes the accuracy as the closeness of agreement between a measured quantity value and a true quantity
value of a measured object (ISO/IEC GUIDE 99:2007(E/F) [7]. A system with high accuracy has the capability to
produce an object that is closely comparable to the CAD file. According to Minev R. and Minev Ek. [4], the process
accuracy in the X and Y plane is usually better that in the Z direction. For this reason and because no curling and
growth are affecting upward surfaces the best feature definition and resolution are achieved in X-Y plane. But
Braian M. et al. [7] showed quite different tolerances along the X, Y and Z axes of the polymeric objects
manufactured by four different 3D printers. In conclusion, there is no clear tendency for the higher dimensional
accuracy in the X-Y plane. However, taking into account that the surfaces, parallel to that plane, are the smoothest,
it is preferable the important surfaces to be oriented upwards in the building envelope.
o Shrinkage
Ishida Y. and Miyasaka T. [6] have shown that in the most conditions the all samples’ dimensions were smaller
than that of the virtual 3D model. According to them the FDM printer showed the best accuracy in terms of the outer
diameter and the worst accuracy in terms of the inner diameter and depth, while the MJM and the laser SLA printers
showed the best accuracy for the inner diameter and depth. It was established in [16] that the dimensions of dental
bridges, cast using 3D printed patterns (MJM process), were smaller than that of the 3D virtual model with about 0.1
mm and the maximal deviation was between 0.1mm and 0.2 mm.
 VIIth International Metallurgical Congress, Ohrid 2016

Consequently, in fabricating of cast patterns via 3D printing not only the coefficient of thermal shrinkage of the
metal alloy should be taken into account, but also the shrinkage of the polymer during polymerization or
solidification. In most cases it is not given by the company-producer and should be established with preliminary
experiments. For manufacturing of casting with high dimensional accuracy, the virtual 3D model has to be corrected
with the established shrinkage values.
o Deformations
Currently, objects with dimensions up to 1000 mm along the X, Y, Z directions can be printed [10]. Taking into
account the specific of the AM processes, we should expect that with the growth of the printed object, the
temperature gradient on the surface will increase (MJM, FDM and SLS) which will lead to generating of internal
stresses. In the SLA the incomplete photo-polymerization during the 3D printing can cause internal stresses in the
following final polymerization. As a result the detail deforms.
The most common deformation is so called “curling”. This phenomenon is identified when the edges or the
corners of the part rise above the part-bed surface [4]. It occurs due to a temperature difference between the ready
(sintered, cured, extruded) part and the newly added material. As a corrective measure, the set point values for the
process heaters or the power of the laser has to be increased.
When extra material is sintered or cured on the part, the “growth” phenomenon is observed [4]. In powder
sintering processes (SLS) the growth occurs due to excessive laser power and part-bed temperatures, thus leading to
heat diffusion beyond the part boundaries resulting in oversized parts. In photo-curable technologies (SLA) the
processes are similar and they are due to the penetration of light outside the geometric boundaries of the part. To
avoid this problem, reducing part-bed temperature and the laser power are recommended.
Therefore, the technological parameters – laser power and speed, controlling the temperature, are key factors in
the 3D printing process [10]. Failing to correctly choose one of these parameters may result in defective printed
objects.
o Surface roughness
Because of the nature of AM process, the surface of the fabricated details possesses layered morphology and
higher roughness (Fig. 4). In the 3D printing, the roughness of the objects’ surface depends on the thickness of the
layer and the inclination to the print direction. The larger layer thickness and inclination, the greater roughness
[11,13,17].
Different processes cause different surface roughness. The largest is the surface roughness of the sample created
by FDM printer comparing to the laser SLA and MJM printers (Fig. 4) [6,10]. There is also difference of the
roughness values along the 3D axes. The roughness along the tooth axis of the crown created by laser SLA printer
was the smallest and that along the horizontal direction of the crown created by MJM printer was the smallest [6].
The higher surface roughness is established along Z axes, comparing to that along X and Y axes in the DLP SLA
[17]. As a result of the higher surface roughness of the 3D printed cast patterns, the surface roughness of the samples
cast using them is about 3 times higher than that cast by wax models, produced in silicone mold (Ra=3.387 μm and
Ra=1.312 μm respectively) [18]. The traces of the layered manufacturing can be clearly seen on the surface of the
casting.
The above mentioned disadvantage could be avoided by post processing of the 3D printed cast patterns. The
smooth molding surface of the patterns for sand casting can be obtained by two ways – sanding or solvent
smoothing (for ABS materials) [2]. In the first process the pattern surface has to be grinded with 120- to 320-grit
sand paper. All depressions and layer lines have to be filled in using body filler, glazing putty or spot putty. After
the filler has dried, all surfaces have to be grinded to the desired smoothness. In the second process the solvent is
applied to the pattern to smooth the surfaces. This may be brushed onto the pattern or the pattern can be dipped into
it. Finally the top coat has to be applied on the cast pattern for providing additional abrasion and chemical
resistance. In investment casting the surface finish of a pattern will be replicated in the ceramic shell and transferred
to the metal casting [1]. Therefore, it is important to smooth the surfaces of the patterns to the desired finish level.
Also, the surfaces must be sealed to prevent ceramic slurry from entering the pattern. For this purpose the Finishing
Touch Smoothing Station is used to prepare the patterns. This is a labor-free process that can be completed in less
than five minutes. This process yields a smooth surface finish while preserving dimensional accuracy and protecting

a) b) c)

5 mm 5 mm 5 mm
Fig. 4 Surface roughness of polymeric objects, printed with 3D printers using different AM processes: FDM – a),
DLP stereolithography – b) and laser stereolithography – c). The details are printed on the same virtual 3D model.
 VIIth International Metallurgical Congress, Ohrid 2016

delicate features. If such a device is not available, the smooth surface of the patterns for investment casting can be
obtained the same ways as in the patterns for sand casting.

Conclusion
The possibilities of 3D printing technologies for production of cast patterns for investment and sand casting are
analyzed in the present study. The application of 3D printing in the production of cast patterns leads to both reduced
fabrication time and cost. It allows usage of interchangeable components and automated pattern production.
3D printing systems use different AM processes, affecting the dimensional accuracy, surface roughness and the
overall object quality. For manufacturing of precise cast pattern, guaranteeing casting with high quality, it is
important to know the advantages and disadvantages of different AM processes, the main manufacturing problems
and the ways to avoid them.
It was found that all samples’ dimensions were smaller than that of the virtual 3D model independently of the
printer used – FDM, MJM or SLA. Thus is most probably due to the shrinkage of the polymer during
polymerization or solidification. To avoid that, the virtual 3D model has to be corrected with an experimentally
derived value. Different AM processes cause different surface roughness. The largest is the surface roughness of the
sample created by FDM printer comparing to the SLA and MJM printers. That is why, for the smooth surfaces, the
post processing of the 3D printed cast patterns is needed. For 3D printing of cast patterns with high quality and
minimum deformations, the technological parameters of the equipment have to be correctly chosen.
Nowadays, there is a great variety of AT. Many new AM processes are developed recent years, which are not
investigated in details. So, continuous research is needed for their application in different industrial branches.

References
1. TECHNICAL APPLICATION GUIDE: Investment Casting with FDM Patterns, Doc. No. TAG 06-02, 19 April
(2011), Stratasys, 11 p., www.stratasys.com (Accessed 20 May 2016).
2. TECHNICAL APPLICATION GUIDE: FDM for Sand Casting, Stratasys, 12 p., www.stratasys.com (Accessed
20 May 2016).
3. Dikova T, Dzhendov D, Simov M, Katreva-Bozukova I, Angelova S, Pavlova D, Abadzhiev M, Tonchev T.
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