Precision casting with 3D printed burnout patterns is an increasingly valued technique in industry, enabling the production of metal parts with complex geometries and high dimensional accuracy. This process, which replaces traditional methods based on wax or polystyrene foam patterns, uses master patterns printed with photopolymer resins through technologies such as stereolithography (SLA).
Context and challenge
One of the main advantages of this technology is the ability to manufacture parts with extremely complex geometries, without the need for draft angles, clearances, joints, or internal cores. Precision can reach 20 micrometers, significantly reducing tolerances and the time required for finishing operations. 3D printed photopolymer patterns also exhibit superior mechanical strength compared to wax or foam patterns, which is particularly important in the production of large parts. Additionally, printing lightened internal structures (such as lattices or cellular cavities) reduces resin consumption, printing time, and residues during the burnout phase, minimizing internal pressure and ash content. In a context marked by difficulties in acquiring spare parts—particularly for equipment imported from the European Union, Japan, or the United States—3D printed burnout pattern casting technology enables reproduction of parts from the original physical model, even without access to the CAD file or technical drawing.
The solution or technology
Kings 3D 3D printers have demonstrated high reliability in this type of application, combining high resolution, large print volumes, and compatibility with resins ideal for clean burnout. They are an effective and more accessible alternative to conventional high-cost equipment, offering rapid and sustainable return on investment. The typical workflow includes: 3D scanning of the original part (when no CAD model exists) and modeling in computer-aided design software; 3D printing of the master pattern, followed by post-processing; application of feed channels, if not integrated into the pattern; formation of the ceramic shell or external mold; burnout of the pattern and calcination of the mold; filling the mold with molten metal; removal of the shell and finishing of the metal part.
Industrial applications
Casting with 3D printed burnout patterns is ideal for rapid production of single parts or short series, as well as for replacement of discontinued technical components. This method enables production of components such as housings, impellers, technical bodies, gears, turbines, among other parts with sophisticated and demanding geometries, with applications in sectors such as aerospace, automotive, jewelry, and mechanical engineering.
Results and benefits
The technology enables manufacturing of parts with extremely complex geometries without the need for draft angles, clearances, joints, or internal cores. Precision can reach 20 micrometers, significantly reducing tolerances and the time required for finishing operations. Printing lightened internal structures reduces resin consumption, printing time, and residues during the burnout phase. Kings 3D printers offer rapid and sustainable return on investment, being a more accessible alternative to conventional high-cost equipment.
How NM3D can help
At NM3D Ibérica, we make available to the market the most advanced technologies to integrate 3D printing into precision casting processes. If you are looking for efficiency, versatility, and quality in the production of complex metal parts, contact us. Email: sac@nm3diberica.com
Would you like to assess this solution for your application?
At NM3D Ibérica, we make available to the market the most advanced technologies to integrate 3D printing into precision casting processes. If you are looking for efficiency, versatility, and quality in the production of complex metal parts, contact us.