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This paper seeks to review the industrial applications of state‐of‐the‐art additive manufacturing (AM) techniques in metal casting technology. An extensive survey of concepts, techniques, approaches and suitability of various commercialised rapid casting (RC) solutions with traditional casting methods is presented.

The tooling required for producing metal casting such as fabrication of patterns, cores and moulds with RC directly by using different approaches are presented and evaluated. Relevant case studies and examples explaining the suitability and problems of using RC solutions by various manufacturers and researchers are also presented.

Latest research to optimize the current RC solutions, and new inventions in processing techniques and materials in RC performed by researchers worldwide are also discussed. The discussion regarding the benefits of RC solutions to foundrymen, and challenges to produce accurate and cost‐effective RC amongst AM manufacturers concludes this paper.

The research related to this survey is limited to the applicability of RC solutions to sand casting and investment casting processes. There is practically no implication in industrial application of RC technology.

This review presents the information regarding potential AM application – RC, which facilitates the fabrication of patterns, cores and moulds directly using the computer‐aided design data. The information available in this paper serves the purpose of researchers and academicians to explore the new options in the field of RC and especially users, manufacturers and service industries to produce casting in relatively much shorter time and at low cost and even to cast complex design components which otherwise was impossible by using traditional casting processes and CNC technology.

The purpose of this paper is to demonstrate the applicability of an indirect rapid tooling technique to the autoclave forming of carbon fibre reinforced plastic laminates.

A rapid prototyping machine was used to process a photo elastic resin to fabricate the pre‐moulds. Liquid particle‐filled epoxy resin was poured in the pre‐mould and cured in an oven. Real autoclave process conditions were then applied to the mould several times to assess the geometrical stability and the accuracy of the produced parts, measured using a laser 3D scanner.

This paper reports the procedures developed for the rapid manufacture of carbon fibre reinforced plastic components.

The method is applicable to components of small to medium dimensions (max 500 mm).

This is a pioneer attempt towards the rapid manufacturing of high performances composite components. It has been presented for patenting purposes (Gian Luca Monti, Ezequiel Poodts, Giangiacomo Minak, and Cristiano Fragassa. Pat. Pending Nr. PS2010A000026, 2010).

This paper presents results from the testing and benchmarking of a slip cast 316 stainless steel injection moulding tool. A brief out line of the slip casting process and the test cavity geometry is given as well as a discussion of some of the commercial alternative methods of forming injection moulding cavities. The calculations for the slip cast test cavity cost and lead time are given and comparisons between slip casting tool formation and alternative methods are made. The paper concludes that the slip casting method has potential in replacing some of the other tooling methods.

Recent developments in rapid prototyping provide evidence of the maturing of some areas of application. New applications continue to surface and new systems/processes are being introduced on a regular basis. The Fifth International Conference on Rapid Prototyping (Dayton, Ohio, 1994) provided an opportunity to bring together leaders in the commercial development and application of RP technology and to hear their perspectives on the current capabilities and future directions. A “Manufacturers round table” provided the forum for the audience to submit questions. Relates participants’ responses.

The purpose of this paper is to review available technologies, analyse their features, propose a new approach of 3D sand mould printing based on line forming, introduce the manufacturing principle and show advantages of this approach, especially for larger parts with large Z steps in the build, such as 2 mm stepwise.

This paper introduces 3D sand mould printing, compares and analyses technological process and existing fabrication approaches among available technologies first. Then, a new approach of 3D sand mould printing is proposed to improve build speed. In addition, the proposed system will be analysed or benchmarked against existing systems.

A new approach based on line forming of sand mould printing is put forward by reviewing and analysing available technologies, to improve build speed from the aspect of basic moulding movement instead of optimization of moulding methods and process parameters. The theoretical calculation and analysis shows that build speed can be improved greatly, and it is more suitable for the manufacture of large-scale casting’s sand mould when considering dimensional accuracy and printing error, as well as uniformity of each layer.

The specific implement scheme of line forming and nozzle’s specific structure of this new approach need further study.

Much higher build speed of 3D sand mould printing with new approach brings evident implication for moulds companies and manufacturing industry, having a far-reaching influence on the development of national economy.

This paper reviews available technologies and presents a new approach of 3D sand mould printing for the first time. Analysis of the new approach shows that this new method of sand mould printing can boost build speed greatly. So, its application prospect is great.

Reviews, for the USA, Europe and Japan, the current state of development and application of rapid prototyping techniques and their impact on time‐to‐market for new products. These techniques, which are still undergoing rapid development, have already had a dramatic effect on reducing the time‐to‐market for new products by between 60 per cent and per cent and on reducing the cost‐to‐market by between 40 per cent and 70 per cent. Concludes that although the US is ahead of the rest of the world in terms of depth of experience and range of techniques, Europe and Japan are catching up fast in terms of experience and applications. Gives guidelines for the managers of manufacturing companies on the importance of the techniques, the selection of the most appropriate system and how to obtain most of the techniques adopted.

The selective laser sintering (SLS) process is one of the leading rapid prototyping techniques. This paper presents two rapid tooling (RT) methods based on the SLS process. The first method employs the SLS process to build tooling inserts in copper polyamide that can be used for fabrication of a limited number of pre‐production parts in the same material and manufacturing process as the final production parts. The second method, the RapidTool^TM process, is a RT solution for manufacture of pre‐production and production tools for injection moulding and die‐casting. The paper also discusses the applications and limitations of these RT methods.

Rapid tooling can be seen as the second wave in rapid prototyping because, with rapid tooling, the production process can be prototyped instead of the final product. This article discusses and compares several existing processes available for rapid tooling. For each process, the product size and the number of shots is estimated. Since this text was part of the Internet Conference on Rapid Prototyping, a summary of the reactions from the participants is also given.

The purpose of this study is to highlight the direct fabrication of rapid tooling (RT) with desired mechanical, tribological and thermal properties using fused deposition modelling (FDM) process. Further, the review paper demonstrated development procedure of alternative feedstock filament of low-cost composite material for FDM to extend the range of RT applications.

The alternative materials for FDM and their processing requirements for fabrication in filament form as reported by various researchers have been summarized. The literature demonstrates the role of various post-processing techniques on surface finish of FDM prints. Further, low-cost materials for feedstock filament have been investigated experimentally to check their adaptability/suitability for commercial FDM setup. The approach was to realize the requirements of FDM (melt flow rate, flexibility, stiffness, glass transition temperature and mechanical strength), necessary for the successful run of an alternative filament. The effect of constituents (additives, plasticizers, surfactants and fillers) in polymeric matrix on mechanical, tribological and thermal properties has been investigated.

It is possible to develop composite material feedstock as filament for commercial FDM setup without changing its hardware and software. Surface finish of the parts can further be improved by applying various post-processing techniques. Most of the composite parts have high mechanical strength, hardness, thermal stability, wear resistant and better bond formation than standard material parts.

Future research may be focused on improving the surface quality of parts fabricated with composite feedstock, solving issues related to the uniform distribution of filled materials during the fabrication of feedstock filament which in turns further increases mechanical strength, high dimensional stability of composite filament and transferring the technology from laboratory scale to various industrial applications.

Potential applications of direct fabrication with RT includes rapid manufacturing (RM) of metal-filled parts and ceramic-filled parts (which have complex shape and cannot be rapidly made by any other manufacturing techniques) in the field of biomedical and dentistry.

This new manufacturing methodology is based on the proper selection and processing of various materials and additives to form high-performance, low-cost composite material feedstock filament (which fulfil the necessary requirements of FDM process). Finally, newly developed feedstock filament material has both quantitative and qualitative advantage in RT and RM applications as compared to standard material filament.