06-09-2017, 02:42 PM
DSPC (Direct Shell Production Casting) produces ceramic molds for metal castings directly from 3D CAD designs. No tools or patterns are required. DSPC uses three-dimensional printing technology to produce ceramic cast molds using a layer-by-layer process.
The CAD file of the designed part is transferred via modem or magnetic tape to the Shell Design Unit (SDU) of the DSPC system. The SDU operator then designs the ceramic mold to melt the metal part by adding the gated system to the part geometry and converting the updated file into a cavity file in the CAD space. This is a one-time process after which many identical ceramic molds could be generated. The cavity file for the ceramic mold is then used to automatically generate the ceramic casting mold.
The ceramic mold is created in layers. The manufacturing process involves three steps per layer. First, the ceramic packaging model is "sliced" to produce a cross-section of the ceramic mold. Secondly, a layer of fine powder is spread by a roller mechanism. Thirdly, a multi-jet printhead moves through the section, depositing the binder in regions corresponding to the cross-section of the mold.
The binder penetrates the pores between the powder particles and bonds them together to form a rigid structure. Once a given layer has been completed, the ceramic wrap model is again sectioned, in a slightly higher position, and the process is repeated until all the layers of the mold are concreted. The DSPC mold is cleaned after excess dust, baked and poured with molten metal.
A DSPC mold may contain an integral ceramic core, producing a hollow metal part. Virtually any molten metal can be cast in DSPC molds. Automotive parts have already been manufactured in aluminum, magnesium, ductile iron and stainless steel.
The DSPC machine is like a three-dimensional printer that uses the computer-aided design of the designer to create the actual ceramic casting molds. Therefore, it speeds up the design and functional testing of new automotive components such as engines, transmissions and turbochargers. Parts of the first article, made directly from the customer's CAD, are delivered in days. Importantly, any design change is easily incorporated into the CAD space, which provides definitive configuration control and ensures that all design changes are properly documented.
With DSPC, the production tools (molds, patterns and core boxes) are molded as net tools from the CAD file of the approved part. This tool is now created only once, ensuring a smooth and cost-effective transition from the first part of the article to production. It eliminates the need for temporary tools (prototypes), as well as the huge monetary disbursements associated with prototype tools that were previously considered. With DSPC, you can create an indefinite number of design iterations, including testing the design with different alloys, without the costly and time-consuming to produce tools with each step.
The CAD file of the designed part is transferred via modem or magnetic tape to the Shell Design Unit (SDU) of the DSPC system. The SDU operator then designs the ceramic mold to melt the metal part by adding the gated system to the part geometry and converting the updated file into a cavity file in the CAD space. This is a one-time process after which many identical ceramic molds could be generated. The cavity file for the ceramic mold is then used to automatically generate the ceramic casting mold.
The ceramic mold is created in layers. The manufacturing process involves three steps per layer. First, the ceramic packaging model is "sliced" to produce a cross-section of the ceramic mold. Secondly, a layer of fine powder is spread by a roller mechanism. Thirdly, a multi-jet printhead moves through the section, depositing the binder in regions corresponding to the cross-section of the mold.
The binder penetrates the pores between the powder particles and bonds them together to form a rigid structure. Once a given layer has been completed, the ceramic wrap model is again sectioned, in a slightly higher position, and the process is repeated until all the layers of the mold are concreted. The DSPC mold is cleaned after excess dust, baked and poured with molten metal.
A DSPC mold may contain an integral ceramic core, producing a hollow metal part. Virtually any molten metal can be cast in DSPC molds. Automotive parts have already been manufactured in aluminum, magnesium, ductile iron and stainless steel.
The DSPC machine is like a three-dimensional printer that uses the computer-aided design of the designer to create the actual ceramic casting molds. Therefore, it speeds up the design and functional testing of new automotive components such as engines, transmissions and turbochargers. Parts of the first article, made directly from the customer's CAD, are delivered in days. Importantly, any design change is easily incorporated into the CAD space, which provides definitive configuration control and ensures that all design changes are properly documented.
With DSPC, the production tools (molds, patterns and core boxes) are molded as net tools from the CAD file of the approved part. This tool is now created only once, ensuring a smooth and cost-effective transition from the first part of the article to production. It eliminates the need for temporary tools (prototypes), as well as the huge monetary disbursements associated with prototype tools that were previously considered. With DSPC, you can create an indefinite number of design iterations, including testing the design with different alloys, without the costly and time-consuming to produce tools with each step.