This paper presents results of a research on the possibilities of applying 3D printed casting models for small production series as alternative to traditional tooling production on automated DisaMatch mould production lines. The main task was to verify and compare the dimensions of the 3D printed models before and after moulding process. The paper discusses main advantages and disadvantages of the 3D printing methods used like FDM (Fused Deposition Modeling)/FFF (Fused Filament Fabrication), SLA (stereolitography) and DPP (Daylight Polymer Printing). Measurement of casting model outside dimension change resulting from moulding sand friction on their surface was made with the use of GOM INSPECT software on the basis of 3D scans made with ATOS TripleScan optical scanner. Hardness of 3D printed models made of ABS, Z-ULTRAT, three different photopolymer resins (from FormLab and Liquid Crystal companies) was verified. The result of the research printed models usability for the foundry industry was presented.
A significant development of the foundry industry contributes to the creation of high reliability and operational strength castings so that they meet specific standards in accordance with customers’ needs. This technology, however, is inseparably connected with casting defects in finished products. Cast products are subject to various defects which are considered acceptable or not, which is conditioned by the alloy chemical composition and strength characteristics, that is, generally – qualities to be agreed between the foundry and the customer. It is the latter that led the authors to research on designing a tool enabling the most reliable possible assessment of the emerging casting defects, which after proper consultations can be repaired and the casting – sold. The paper presents an original tool named the Open Atlas of Defects (OAD), developed for the last few years to support the evaluation of cast iron defects using Non-Destructive Testing (NDT) casting defects analysis tools (DCC card – Demerit Control Chart, Pareto-Lorenz analysis and ABC analysis). The OAD tool structure was presented as an integral part of the original system module for acquisition and data mining (A&DM) in conjunction with the possibilities of using selected tools for defect analysis support on the example of cast iron casting.