RAPID PROTOTYPE CASTINGS - LostFoam.com - Lost Foam ...Title: NEW INNOVATIONS IN LOST FOAM Author: Brian Gustison Created Date: 8/10/2004 4:12:11 PM

RAPID PROTOTYPE CASTINGS RAPID PROTOTYPE CASTINGS

Using the Lost Foam Process Using the Lost Foam Process

to make Prototypesto make Prototypes

Copyright 2004 © Austin Group, LLC. All rights reserved.

LOST FOAM PROTOTYPE CASTINGLOST FOAM PROTOTYPE CASTINGExample Aluminum PartExample Aluminum Part

Air Intake Manifold CADD Data



Air Intake Manifold Pattern Pieces Cut



Air Intake Manifold Partial Pattern Assembly



Air Intake Manifold Casting



Air Intake Manifold Casting



Engine Block Prototype Casting Project



Engine Block Segment D Bottom View



Engine Block Made from Pattern Segments



Engine Block Segment Showing Cored Areas



Engine Block Pattern Assembled



Water Cooled Manifold Exterior Surfaces



Water Cooled Manifold Interior Surfaces



Water Cooled Manifold Casting Engine Face



Water Cooled Manifold Show Face



Prototyping Die Castings Using Lost Foam Prototyping



Thin Wall SectionsCopyright 2004 © Austin Group, LLC. All rights reserved.

LOST FOAM PROTOTYPE CASTING LOST FOAM PROTOTYPE CASTING Example Iron PartExample Iron Part

Agricultural Combine Part – Blade Section


LOST FOAM PROTOTYPE CASTING LOST FOAM PROTOTYPE CASTING Example Iron PartExample Iron Part

Agricultural Combine Part – Net Shape Blades


LOST FOAM PROTOTYPE CASTING LOST FOAM PROTOTYPE CASTING SummarySummary

STATUS

• Virtually any form is possible.

• Patterns reflect molded foam parting and glue lines.



STATUS WITH ALUMINUM CASTINGS

• Success in range of parts.

• 90% cast on first article.

• Detail & surface finish similar to molded foam.



STATUS WITH IRON CASTINGS

• 75% cast on first article.

• Detail & surface finish is lower quality than molded foam.


RAPID PROTOTYPE CASTINGS RAPID PROTOTYPE CASTINGS

Using the Lost Foam Process Using the Lost Foam Process

to make Prototypesto make Prototypes


Documents

RAPID PROTOTYPE CASTINGS - LostFoam.com - Lost Foam ...Title: NEW INNOVATIONS IN LOST FOAM Author: Brian Gustison Created Date: 8/10/2004 4:12:11 PM