Metal Casting Using 3D Printed Mold and Microwave Furnace: The Foundry Lab Process Explained

Foundry Lab's digital casting process leverages 3D printing in a system able to deliver a casting from a CAD file within one day. In this process, a mold is 3D printed from ceramic. The mold is heated in a microwave furnace to melt the metal into the cast form. This casting method can be performed in any industrial setting; it does not require pouring molten metal or any of the resources typical of a foundry. Prototyping and short-run production of castings are among the applications. Peter Zelinski filmed this description of the process during a visit to Foundry Lab's facility in Fremont, California.

[brbubba]

I talked to them at Formnext last year, it was unclear how many castings a single mold could go through.

[zhongmingwang]

Is it true that the mold, right after binder jetting 3D printing, still has loose ceramic powder? How does the mold curing by the microwave furnace work? Does this process enable a nice surface finish for the final cast piece? Thanks!

[PeonOnDope]

Although I like the idea somewhat and admire your commitment, I have to say that the approach looks terrifying. The surface quality looks much worse than an average sand casting with this wall thickness, no localised feeding is provided and mechanical properties are likely to be far below standards with these slow cooling rates. The process cannot be used for more than demonstration parts, and it is very expensive for that, as I can achieve the same effect with a painted plastic print.

[spotlightonpublictelevision]

Spotlight On - The Modern Metal Casting Industry