Z Corporation Z 406 User Manual download pdf (Page 128)

Appendix I

ZCast Design Guide - 10

3 ZCast Advantages

Today, metal casting molds are commonly created by first producing a machined pattern (or

pattern set) that is then used to create the molds. Instead of utilizing this costly and often time

consuming process, the ZCast process utilizes 3D printing to create the molds and mold inserts

directly from CAD data. With the ZCast process, Z Corp. provides the option to skip the pattern

or tooling step, significantly reducing the time required to obtain metal castings, while also

reducing the cost.

The production of prototype castings using conventional methods can often take several weeks

and be prohibitively expensive. These constraints limit the number or preclude the production of

metal prototypes during the development process. Specific time and cost savings will depend on

the size and complexity of the desired part, but can also be substantial for most customer needs.

Castings can be produced in as few as one or two days for a fraction of the cost of traditional

tooling.

3.1 The Material

ZCast

501 powder is a plaster-ceramic composite suitable for casting low temperature metals

(aluminum, magnesium, and zinc). Tests conducted by Z Corp. and it’s foundry partner (Griffin

Industries) have shown results that mimic traditional sand casting finishes and tolerances. Many

successful castings have been made in 356, 390 and 319 aluminum as well as zinc, bronze, and

magnesium.

The ZCast material set can be used on the Z810 Large Format 3D Printer, the Z406 3D Printer

and the ZPrinter

3D Printer.

WARNING

Do not use ZCast 501 molds with molten ferrous metals or

other metals with pouring temperatures above 1100

(2000

F). The molds can suddenly fail unexpectedly

releasing entrapped gases and molten metal causing

serious personal injury.

3.2 Design Freedom

In addition to reducing the time and cost to create a prototype casting, the ZCast process also

provides the freedom to produce complex castings that previously were difficult or impossible to

produce using conventional tooling methods. One of the powerful features of the ZCast process

is the freedom to incorporate undercuts and channels in the molds. Runners and vents can be

formed inside the mold that are otherwise impossible to machine; cores can be integrated into the

mold, minimizing the number of parts and simplifying setup. For prototype parts, this greatly

simplifies the mold design process.

Design alternatives include:

• The Direct Pour Method involves printing an entire mold, cores and all, in the ZCast

material. This usually uses the most material, but allows for virtually no set-up time and

very quick production of your prototype casting.

• The Shell Method involves printing only a thin (½ inch thick) mold to surround the entire

part. This shell is then backed with traditional foundry sand in a flask to create a mold

suitable for pouring. This helps to minimize the amount of ZCast material used and is

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Z Corporation Z 406 User Manual Page 128

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