Simulation, Optimization and Design of 3D Printed Sand Molds for Cast Metal Parts

Additive manufacturing of metal components has brought about new approaches for optimization and design as the process inherently allows far more geometric freedom than traditional manufacturing techniques. This geometric freedom can readily be translated into improved functionality, performance, and/or weight reduction with careful design. However, there are currently prohibitive limitations on maximum part size, high costs, and in some cases quality assurance questions that constrain the uptake of processes in industry for making final parts. For these reasons, an alternative approach has been investigated for design of advanced cast metal parts that are created in additive manufactured sand molds.