The study aims to optimize the 3D printing process parameters of sand molds used for electrofused refractory casting.

Traditional sand mold manufacturing involves several steps (patterning, molding, assembly) which are time and cost consuming. The main limitation of the process being that complex shapes are avoided or impossible to make due to a high production cost. In this way, sand molding via 3D printing is investigated to enable complex shape manufacturing.

In this study, the possibility to manufacture sand molds via Binder Jetting technology is presented. Several printing recipes have been set up and tested to understand the printing parameters influence on the printed mold properties. Mechanical, thermal and structural characterizations have enabled to choose different mold recipes for electofused refractory castings. Different molding geometries have also been tried to investigate the resolution that can be reached using 3D printed molds. After casting, the refractory’ surface has been observed with the aim to link the surface defects with the mold properties.