Oct 15, 2023

The Engineer

The production of prototype molds by traditional manufacturing technologies is time-consuming and financially unsustainable. To speed up the manufacturing of prototype molds various techniques have been developed to produce a mold without using the existing model.

One of the hottest techniques that currently used in modern foundries is the method of reverse engineering. This method involves obtaining the virtual 3D model from the existing part or model using a 3D scanner. A part/model is digitalized through the computer scanner. Once the spatial coordinates are identified on the surface of the part, a CAD model is generated through it.

The CAD model is then used to create the patternless mold. This process involves the sand printing of mold in a layer-by-layer fashion. Layers of sand are deposited and are selectively hardened in areas according to the shape of the required mold by using binders. The binder is deposited using a moveable print head with a multi-jet or single jet nozzle.

The process is repeated until the entire mold is obtained by the addition of layers one after the other. The loose sand around the hardened part acts as a support. In this way, 3D printing offers quick and efficient production capabilities which have expanded beyond the limitations encountered when the technology first rose to prominence. As no patterns in their formation, the molds obtained are also referred to as patternless molds. The sand mold is created in two halves that are then they joined together after hardening and coating. The process requires no baking or post-processing.

The key advantages of this process are the elimination of expensive tooling, shorter lead times as printing takes place directly from CAD data file, freedom in design, improvements in product quality and efficiency, better functionality since complex core designs are possible, and easy updating of CAD models to allow for re-printing.

Once detached from the drawbacks of traditional mold production these revolutionary techniques enable one-off castings and prototypes to be produced cheaper and faster than ever before. The complete process is shown in the Figure.

As the industry shifts toward reverse engineering technology in Patternless manufacturing, Omnidex once again has taken the lead in providing high-quality products for customers in a very short time. Creating Patternless molds for casting using traditional methods was time-consuming.. But with the use of reverse engineering we are now producing products from Patternless manufacturing technology in a shorter period for our customers.

At Omnidex Castings, we are constantly looking for ways to improve the foundry production experience by cutting time to market, adding flexibility, reducing the lead time from design to production, allowing for smaller batch sizes, and enabling prototype production with more complicated designs.

Contact our Engineering Team to learn more about our diverse manufacturing and engineering service and how we can help on your projects.

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