3D PROTOTYPING

Farrar is now offering 3D Sand Printing to save both time and money in new product development.  We turn CAD files into blocks of sand that can have iron poured into them without any tooling.  Therefore, casting lead times can be reduced greatly; sometimes as low as 1–2 weeks—without expensive tooling!

Our Process:

  1. We create casting shape, core shape, and pattern shape.
  2. We create block models of the cope and drag.
  3. The cope and drag and core models are then printed with furan sand.
  4. Casting prototypes are then poured.
  5. Parts are then shipped; sometimes as short as 2 weeks.

Examples of our 3D Prototyping

Challenge #1:
Customer sent in a machined model of a part to quote 4 different prototypes to properly test (as they were unsure of the design). (see figure 1)

Farrar 3D Solution:

  1. We added machine stock to the part to create the casting shape.
  2. A core was created from the casting geometry to produce a hole in the part.
  3. Coreprints and a gate were added to the casting model to create the pattern shape.
  4. A block model was created of the drag half of the mold, from the pattern.
  5. Another block model was made for the cope. Note the 3/16” vent holes added to the model. (see figure 2)
  6. The cope and drag models and the core model were then printed in furan sand. (see figure 3)
  7. We used standard rectangular patterns for locating the sand block in our mold.
  8. All components were set into the mold, ready to close the mold and pour.
  9. Iron was poured into the mold with gating attached. (see figure 4)
  10. Completed casting was ready to be ground.
  11. Finished machined casting. (see figure 5)
  12. Lead time for this project was only 2 weeks.

Note, we can occasionally reduce the time to 1 week with an expedite fee. 

Challenge #2
Customer needed prototypes to test.

Farrar 3D Solution:

  1. We imbedded 2 parts inside of the block.
  2. We created the drag block model. (see figure 6)
  3. We created the cope block model. (see figure 6)
  4. Then sand blocks were created from the models. (see figure 7)
  5. Blocks were assembled.
  6. House patterns was made to accept the sand blocks.
  7. Drag lock was set into the mold.
  8. Both blocks were set in the mold that is ready to be closed up and poured.
  9. Poured mold at shakeout, ready to degate the castings
  10. Castings were finished and ready to be shipped. (see figure 8)

Note, the partial hold that goes through the part had no draft on it, as 3D printing of sand does not require draft, unlike regular molded parts.

 

 

 

 

 

 

 

 

 

 

 


Figure 1.


Figure 2.


Figure 3.


Figure 4.


Figure 5.


Figure 6.


Figure 7.


Figure 8.

Our green sand foundry has exclusively poured all grades of ASTM A536 Ductile Iron since 1967.
We print molds & cores directly from CAD for prototypes with the shortest lead times!
Farrar's internal capabilities of a foundry, machine shop, and heat treat facility give it the unique ...
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