The method used to make a set of art castings. Using 3D printing technology to make complex sand cores, not possible by conventional processes.

1. Metal Casting
Using 3D Printing Technology

2. The Idea
• I wanted to create a casting using 3D printing
of sand cores but also….
• The shape had to be very difficult to produce
by conventional core making processes
• This presentation shows the process used to
create the sculpture

3. A complex shape, very difficult to
make in metal by conventional
(sand casting) means

4. Many undercuts in different directions

5. After the design is done…
(3D ProEngineer)

6. ..we add features for metal flow and to
allow the gas to escape

7. Cores are designed to allow easy
preparation

8. Base core

9. Middle core

10. Upper core with metal in-gate and gas
outlets

11. Lower core with locating features

12. Middle Core with locating features

13. Upper core with locating features

14. Cores are printed by
www.hoosierpattern.com

15. Cores are removed from machine

16. Loose sand removal

17. Upper core with locating features

18. Middle core with locating features

19. Core assembly

20. Lower and middle cores

21. Core assembly

22. Pour metal and clean the casting

23. Remove excess metal and polish

24. Highlights in the sunshine

25. martindirker@gmail.com