{"id":41264,"date":"2021-01-08T12:33:22","date_gmt":"2021-01-08T17:33:22","guid":{"rendered":"https:\/\/www.shapeways.com\/blog\/?p=41264"},"modified":"2021-01-08T12:33:24","modified_gmt":"2021-01-08T17:33:24","slug":"using-powder-materials-to-create-3d-printed-molds-for-casting","status":"publish","type":"post","link":"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting","title":{"rendered":"Using Powder Materials to Create 3D Printed Molds for Casting"},"content":{"rendered":"\n

Why\npowder-based materials continue to be so present in 3D printing<\/strong><\/h3>\n\n\n\n

Powder-based\nmethods in 3D printing, generally revolving around technology like selective\nlaser sintering (SLS), are prevalent in manufacturing today, becoming more\nnecessary than ever for powerful applications requiring performance and safety.\nModern designers and engineers rely on plastic powders, metal powders, and a\nrange of impressive techniques to fabricate robust tools and critical parts for\nimportant industries like aerospace and the automotive industry. And although\norganizations like NASA and a handful of car manufacturers may have known about\n(and have been using) 3D printing since its inception, the secret is certainly\nout\u2014after decades under wraps.<\/p>\n\n\n\n

Although resin\nand powder-based technology both tend to offer better accuracy and precision in\nthe finished 3D printed product, with SLS, supports are not required as\nunsintered powder surrounding the parts acts as a convenient support system\nduring the process. Eliminating supports also offers enormous advantage for\nusers who may have already done their time trying to bolster overhangs and\nbridges, wasting extra material, creating more work in the end, and possibly\nopening up parts to vulnerability in terms of scratching or harm during\npost-processing. Without added effort expended in removing supports, users can\nturn their attention to valuable processes like testing prototypes and new\nparts. More complex parts can be easily created too, to include connecting and\nmoving parts.<\/p>\n\n\n\n

Materials\nfor 3D printed molds may be made from nylon, plastic, metal, or even sand<\/strong><\/h3>\n\n\n\n

Users are\ngenerally interested in fabricating molds so that they can make multiple copies\nof one object or a part. The 3D printed mold acts as a vehicle for liquid which\nthen hardens inside during the casting process, resulting in the desired\nstructure (also referred to as the casting, making the terminology a bit\nconfusing). <\/p>\n\n\n\n

While durable nylons like the Shapeways\u2019 Versatile Plastic<\/a> (also known as Nylon 12 plastic or PA12) are suitable for making jewelry and technical accessories, industrial users also rely on them to make a wide range of mechanical parts, fixtures, cases\u2014and in the medical field, even prosthetic devices for amputees in need of limb replacements. Versatile plastic can also be used to create sturdy molds for SLS 3D printing, along with Thermoplastic Polyurethane<\/a> (TPU), which is often viewed as a good substitute for silicone in molds, due to its extreme flexibility. MJF Plastic PA12<\/a>, another material well-suited for applications such as mechanical parts, cases, drones, and prosthetics, can also be used via Multi Jet Fusion technology for creating master patterns leading to casting. <\/p>\n\n\n\n

Users may employ sandstone<\/a> for 3D printed molds in some cases too, although it is more brittle and requires very careful handling. There could also be serious questions over what is used for casting, as filling a sandstone mold with hot metal would most likely cause it to degrade quickly, and intensely. (Sandstone is also used in other industrial applications such as eyeglass frames, mechanical parts, drones, and again\u2014even prosthetics.)<\/p>\n\n\n\n

Metal 3D printing is one of the hottest technologies in manufacturing today, especially as industrial users can look forward to the opportunity for building stronger parts that are lighter in weight. For casting though, metal powders (stainless<\/a> steel, steel<\/a>) are used to create a variety of helpful molds (as well as the castings themselves), from assisting in jewelry making, to stealing away some of the tasks typically relegated to foundries. <\/p>\n\n\n\n

3D Printed\nMolds Are Disrupting Traditional Methods as Old as the Middle Ages<\/strong><\/h3>\n\n\n\n
\"A
3D printed mold for glassblowing by designer Tim Belliveau<\/a><\/em><\/figcaption><\/figure><\/div>\n\n\n\n

Traditionally\nengaged in the process of making molds and casting, foundries are factories\ndedicated to casting molten metal which is then solidified into the specific parts\nrequested by customers. These types of establishments have been around since\nthe 1400s formally\u2014but traditional casting methods are thought to go back as\nlong as 5,000 years ago for production of a variety of substantial metal\nproducts to include ammunition. <\/p>\n\n\n\n

As 3D printing\nhas swept through the mainstream and maintained a strong presence over the last\ndecade especially, traditional businesses like foundries have been forced to\ngive up at least some of their profits to the additive manufacturing industry.\nAgain, the ability to print without supports makes a huge difference, as well\nas being able to print multiple parts in one run. 3D printing is often referred\nto as the fourth industrial revolution due to a long list of benefits\noutweighing traditional manufacturing\u2014from greater affordability in the long\nrun to better speed in turnaround for customers, the ability to make obsolete\nparts, lightweight parts, and in many cases\u2014parts that could never have been\ncreated at all with traditional technology. <\/p>\n\n\n\n

It might be hard\nto imagine that such a long-lasting trade could suddenly begin to disappear,\nbut time will tell in terms of consumer demand from the industrial level. Industrial\nmetal 3D printers are very costly though, and may be the saving grace for\nfoundries worried about going out of business due to an upstart like progressive\ndigital fabrication.<\/p>\n\n\n\n

Just the fact\nthat a 3D printing enthusiast could fabricate, test, and use functional molds on\ntheir own (and create their own mini-production line) speaks volumes for the\ntechnology. The unprecedented independence allowed in creation and subsequent\nproduction, as well as providing a ripe scenario for innovation like the world\nhas never seen before continues to make 3D printing enticing to the public.\nDisruption is also a major factor, and perfectly demonstrated here as the\nnormal balance for foundries is being rocked more and more with 3D printing\ngarnering interest worldwide, and moving in on age-old production systems.<\/p>\n\n\n\n

Casting\nwith 3D printing means better speed, and improved savings on the bottom line<\/strong><\/h3>\n\n\n\n

No matter what\nyour 3D printing level of expertise is so far, it is important to understand\nwhat materials are available to you, and why they are used in different techniques.\nFrom the desktop realm, and large-format industrial manufacturing too, fused\ndeposition modeling (FDM) is now the most ubiquitous technique, accompanied by a\nmassive\u2014and ever-expanding\u2014industry centered around sales of thermoplastic filaments\n(mainly in the US). Still though, FDM is often forced to take a back seat in\ncomparison to the more classic forms of 3D printing, invented decades ago for\nrapid prototyping in engineering.<\/p>\n\n\n\n

Powder-based\ntechnologies differ from extrusion vastly. Created back in the 80s by Dr. Carl Deckard and Dr. Joe Beaman\nat the University of Texas at Austin, Selective Laser Sintering (SLS) 3D\nprinting binds powder particles together with a laser. This occurs after\nthe 3D model is designed and then sliced, creating the layers to be deposited\nuntil the structure is complete. Metal, plastic, ceramics, and other types of\npowder can be used to create castings for prototypes, along with low-volume\nbatch production of functional parts. Other powder-based technologies like\nbinder jetting are expected to continue on as a highly sustainable production\nmethod due to the incredible speed at which they work, producing large volumes\nof parts.<\/p>\n\n\n\n

From prototyping\nto the manufacturing of products that are not only functional, but\nhigh-performing, the evolution of FDM 3D printing and continued popularity is\nundeniable; however, the heavy hitters, the originals, the formative\ntechnologies like selective laser sintering (SLS) and stereolithography (SLA)\ncontinue to perform solidly within additive manufacturing, and are relied on\nfor higher quality prototypes and end use parts resulting in better form and\naccuracy. While these technologies may have some desktop 3D printing counterparts,\noverall, industrial users rely on them with industrial hardware and software to\nmanufacture complex parts that will stand the test of time, whether in terms of\neveryday tools or rocket parts.<\/p>\n\n\n\n

No matter what\ntype of technology you use, learning to use molding processes properly could benefit\nyou greatly in the future. Such knowledge offers a valuable skill set, whether\nyou are using your learning on the job or for your own projects. While we are\nall aware of the intrinsic, revolutionary benefits of 3D printing in terms of\nthe ability to customize and make on-demand products, molds allow you to create\na veritable low-volume factory setting where parts are replicated identically\neach time. This ability offers significant advantage to a business of any size,\nallowing them to design parts, print molds, cast, and perform manufacturing\nduties without having to wait on or pay a middleman. 3D printing molds can be a\ngreat way to reserve capital in terms of production too, although investment in\ntechnology may be of concern.<\/p>\n\n\n\n

Direct Casting Leads to\nFaster Mass Production of Your Product<\/strong><\/h3>\n\n\n\n

In casting, the\nrequirements are simple, as there must be a 3D model and then a mold which is\nmade up of the product features in negative detail. Using investment casting in\n3D printing (also traditionally known as lost wax casting as hot metal\nintroduced to the mold melts the wax insert), metal patterns can be directly\nfabricated\u2014embracing some of the most classic benefits of 3D printing in\nsavings of time, while also greater latitude in design to create complex shapes\nto include cavities and other intricate details. The cooling process is more\nstable, and objects like tools are expected to be more durable and last longer.<\/p>\n\n\n\n

Direct casting\nworks well for large parts or those that could be challenging to work with in\nwax\u2014considered an indirect molding process due to the numerous steps involved.\nIt is, however, as easy as choosing a material to 3D print in the shape of a\ndesign pattern for the mold (to contain liquid casting material), filling it,\nletting it settle, and then removing the object from within. The hardest part\nis perfecting your design. Once you complete that step though, each casting is\nan exact replication of the previous one.<\/p>\n\n\n\n

Seeking\nResources for 3D Printing? Shapeways Can Help<\/strong><\/h3>\n\n\n\n

3D printing allows you to create molds quickly, and also to make changes as needed. The investment is minimal, and the potential is compelling. For high quality castings, it is critical that you understand the process of designing a mold\u2014as well as preparing for how it will pull open so that the structure is not damaged or difficult to remove. And because the capital required to produce industrial-quality molds could put you out of business before you even start, consider using a service like Shapeways to 3D print molds for you\u2014or any other parts or prototypes. <\/p>\n\n\n\n

3D printing services from Shapeways such as SLS allow you to reap the rewards of high-performance, quality materials without having to invest all your business capital in the powerful hardware, software, and materials required for your build.<\/em><\/p>\n\n\n\n

\"learn<\/a><\/figure><\/div>\n","protected":false},"excerpt":{"rendered":"

Why powder-based materials continue to be so present in 3D printing Powder-based methods in 3D printing, generally revolving around technology…<\/p>\n","protected":false},"author":175,"featured_media":38012,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[510],"tags":[1015,2580,1736,2630],"class_list":["post-41264","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-3d-printing-industry","tag-3d-printing-materials","tag-industrial-3d-printing-materials","tag-materials-explainer","tag-powder-materials"],"thumbnail":"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2018\/04\/05-e1524064525209.jpg","yoast_head":"\nUsing Powder Materials to Create 3D Printed Molds for Casting - Shapeways Blog<\/title>\n<meta name=\"description\" content=\"Why powder-based materials continue to be so present in 3D printing Powder-based methods in 3D printing, generally revolving around technology like\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Bridget Millsaps\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"9 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting#article\",\"isPartOf\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting\"},\"author\":{\"name\":\"Bridget Millsaps\",\"@id\":\"https:\/\/prodshapeblog.wpenginepowered.com\/#\/schema\/person\/fff5ced46f867f516113910a747d12f6\"},\"headline\":\"Using Powder Materials to Create 3D Printed Molds for Casting\",\"datePublished\":\"2021-01-08T17:33:22+00:00\",\"dateModified\":\"2021-01-08T17:33:24+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting\"},\"wordCount\":1762,\"commentCount\":0,\"publisher\":{\"@id\":\"https:\/\/prodshapeblog.wpenginepowered.com\/#organization\"},\"image\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting#primaryimage\"},\"thumbnailUrl\":\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2018\/04\/05-e1524064525209.jpg\",\"keywords\":[\"3D Printing Materials\",\"industrial 3d printing materials\",\"Materials Explainer\",\"powder materials\"],\"articleSection\":[\"3D Printing Industry\"],\"inLanguage\":\"en-US\",\"potentialAction\":[{\"@type\":\"CommentAction\",\"name\":\"Comment\",\"target\":[\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting#respond\"]}]},{\"@type\":\"WebPage\",\"@id\":\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting\",\"url\":\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting\",\"name\":\"Using Powder Materials to Create 3D Printed Molds for Casting - Shapeways Blog\",\"isPartOf\":{\"@id\":\"https:\/\/prodshapeblog.wpenginepowered.com\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting#primaryimage\"},\"image\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting#primaryimage\"},\"thumbnailUrl\":\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2018\/04\/05-e1524064525209.jpg\",\"datePublished\":\"2021-01-08T17:33:22+00:00\",\"dateModified\":\"2021-01-08T17:33:24+00:00\",\"description\":\"Why powder-based materials continue to be so present in 3D printing Powder-based methods in 3D printing, generally revolving around technology like\",\"breadcrumb\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting#breadcrumb\"},\"inLanguage\":\"en-US\",\"potentialAction\":[{\"@type\":\"ReadAction\",\"target\":[\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting\"]}]},{\"@type\":\"ImageObject\",\"inLanguage\":\"en-US\",\"@id\":\"https:\/\/www.shapeways.com\/blog\/using-powder-materials-to-create-3d-printed-molds-for-casting#primaryimage\",\"url\":\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2018\/04\/05-e1524064525209.jpg\",\"contentUrl\":\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2018\/04\/05-e1524064525209.jpg\",\"width\":1600,\"height\":1200,\"caption\":\"'Artifacts' 2018. 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