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An Overview
Direct Shell Production Casting (DSPC) fabricates ceramic shells (molds) that can be used to cast metal parts. A DSPC system consists of a shell design unit (SDU) and a shell production unit (SPU). A CAD file containing the data of the designed part is transferred to the SDU. The operator of the SDU, which is essentially a graphics workstation, then designs the ceramic mold by adding the gating system to the data in the CAD file. This updated CAD file is then converted into a cavity file. The ceramic mold can then be automatically fabricated from the cavity file as many times as needed by the SPU. The ceramic mold is built in layers by slicing the model into cross-sections, spreading a fine layer of fine alumina powder with a roller mechanism, and depositing a liquid resinous binder in regions corresponding to the cross-section of the mold with a multi-jet print head moving across the section. This process is repeated for each layer until the entire mold is built. The binder that is deposited for each layer penetrates the pores between the powder particles resulting in the layers adhering to each other. The mold can contain an integral ceramic core in order to produce a hollow metal part. Once the mold is built, the excess powder is cleaned away and the mold is fired.
Shells fabricated with this technology can only be used to cast one part. The cast parts tend to have a slightly rougher surface finish.
The process of casting a part once the mold is made, also known as investment casting, is performed in the traditional manner. This technology is ideal for producing castings with complex geometries and castings for prototype testing, marketing samples, or small production runs. Any molten metal can be cast in these molds including aluminum, magnesium, ductile iron, and stainless steel.
This technology was developed by the Massachusetts Institute of Technology (MIT) and has been solely licensed to Soligen Technologies.
Disclaimer
DPT may not provide some of the services and/or techniques presented in the Knowledge Center. For a full list of services we do offer, please visit our rapid prototyping page.
