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Large scale vat-photopolymerization of investment casting master patterns: The total solution

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journal contribution
posted on 2022-11-03, 15:17 authored by Farzaneh SameniFarzaneh Sameni, Basar Ozkan, Sarah Karmel, Daniel Engstrom, Ehsan SabetEhsan Sabet
The material properties and processing of investment casting patterns manufactured using conventional wax injection Molding and those manufactured by vat photopolymerization can be substantially different in terms of thermal expansion and mechanical properties, which can generate problems with dimensional accuracy and stability before and during ceramic shelling and shell failures during the burn-out of the 3D printed casting patterns. In this paper and for the first time, the monofunctional Acryloyl morpholine monomer was used for 3D printing of casting patterns, due to its thermoplastic-like behavior, e.g., softening by heat. However, the hydrophilic behavior of this polymer led to an incorporation of up to 60 wt% of Hexanediol diacrylate, to control the water absorption of the network, which to some extent, compromised the softening feature of Acryloyl morpholine. Addition of a powdered wax filler resulted in a delayed thermal decomposition of the polymer network, however, it helped to reduce the thermal expansion of the parts. The dimensional accuracy and stability of the wax-filled formulation indicated an excellent dimensional tolerance of less than ±130 µm. Finally, the 3D printed patterns successfully went through a burn out process with no damages to the ceramic shell.

Funding

EPSRC Centre for Doctoral Training in Additive Manufacturing and 3D Printing

Engineering and Physical Sciences Research Council

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Alp Engineering Services, Switzerland

History

School

  • Mechanical, Electrical and Manufacturing Engineering

Published in

Polymers

Volume

14

Issue

21

Publisher

MDPI

Version

  • VoR (Version of Record)

Rights holder

© The authors

Publisher statement

This article is an Open Access article published by MDPI and distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).

Acceptance date

2022-10-24

Publication date

2022-10-29

Copyright date

2022

eISSN

2073-4360

Language

  • en

Depositor

Dr Ehsan Sabet. Deposit date: 2 November 2022

Article number

4593

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