Rapid tooling for sand casting using laminated object manufacturing process

It is now possible to generate tooling for near net shape manufacturing processes directly from a CAD database by using computer numerical control (CNC) machining or a variety of rapid prototyping (RP) processes. These methods are widely referred to as rapid tooling processes because the tool geometry is created in a relatively short time. In particular, the use of RP processes has proved to be a cost-effective and time-efficient approach for producing patterns and core boxes for sand casting. However, the suitability of this approach depends on a variety of geometry and process related considerations. Investigates the use of the laminated object manufacturing (LOM) based rapid tooling process in sand casting. Issues discussed include geometry considerations, error sources and propagation, and shrinkage effects. A case study illustrating time and cost savings using the LOM approach is also presented.