FC300 Impeller Casting with 3D-Printed Sand Molds
This project combined casting design, simulation and 3D-printed sand mold production to manufacture a complex FC300 gray cast iron impeller casting.
- Component
- Impeller Casting
- Material
- FC300 Gray Cast Iron
- Mold
- 3D-Printed Sand Mold
PROJECT OVERVIEW
Design, Simulation and Digital Mold Production
The manufacturing route was developed around the component geometry, casting rigging and a digitally produced sand mold. Simulation images were used during engineering review before mold production and casting.
- Component
- Impeller Casting
- Material
- FC300 Gray Cast Iron
- Engineering
- Casting Design and Simulation
- Mold Technology
- 3D-Printed Sand Mold
- Project Scope
- Design to As-Cast Component
Casting Design and Rigging Development
The casting model was prepared together with the proposed runner and feeding configuration. The engineering review considered the relationship between the component geometry, casting orientation, mold sections and rigging arrangement before production.
Casting Simulation Review
Casting simulation was used to review how molten metal progressed through the proposed runner, casting and feeding system before mold production. The staged views supported evaluation of the filling sequence and rigging configuration for this FC300 component.
Staged filling-sequence views from the casting simulation. Color scales are shown as generated by the simulation output and are not interpreted here as specific temperature, velocity, solidification or filling-time values.
Internal Mold Configuration
Section views illustrate the relationship between the component geometry, sand mold sections, cores and casting rigging.
3D-Printed Sand Mold Production
The sand mold geometry was produced directly from the prepared digital manufacturing data. The segmented mold construction allowed the internal geometry, cores and casting rigging to be assembled as part of the production workflow.
The As-Cast FC300 Impeller Before Machining
The FC300 impeller is shown in its as-cast condition after the runner and feeding system have been removed, prior to machining and final finishing.
Views of the As-Cast Component
Additional viewing angles of the as-cast FC300 impeller and the opened mold configuration.
PROCESS SUMMARY
Workflow at a Glance
- 01Casting Design
- 02Rigging Development
- 03Casting Simulation
- 04Sand Mold Production
- 05Mold Assembly
- 06Casting
- 07Mold Opening and Finishing
Need to Produce a Complex Impeller?
Share your drawing, 3D model or existing component with our engineering team. We can review the geometry, material requirements and proposed manufacturing route before production.
