Z Corporation Z 406 User Manual download pdf (Page 134)

Appendix I

ZCast Design Guide - 16

5.3 Designing Molds in your CAD System

Regardless of the method you select, it is likely that some CAD work will be required. It is

necessary to create the most accurate representation of your design digitally, as it will be

represented by a 3D print.

5.3.1 Direct Pour Method

Before addressing the mold design specifics, we will consider the basic steps of designing a mold

using a standard CAD package.

Most middle to high-end CAD packages such as Pro/E, SolidWorks, Catia, Unigraphics, and

Autodesk Inventor, etc. as well as some tooling packages such as Magics Tooling will contain the

tools you need to create a mold. These are the steps required to design a mold:

1. Import part data. It is advantageous to use native files. If it is not possible, next best

would be an IGES or STEP file. If neither choice is available an .STL (sterolithography

slice file) would be suitable with a package like Magics RP. Processing tends to be much

slower when working with .STL files.

2. Add finish stock to machined surfaces, typically 0.080 in (2mm).

3. Apply shrinkage factors based on material to be cast and part geometry.

4. Define and divide out cores, using surfaces generated within the model.

5. Add core prints to the cores.

6. Design the gating system as a positive component around the part to be cast.

7. Encapsulate the part and gating within a larger form (typically a rectangular block).

Subtract the casting and gating and core prints away from the larger block, leaving the

mold cavity.

8. Generate a parting surface and split the mold block.

a b

d e

Figure 5: Combination Method – a) zp102 patterns infiltrated and backed with

epoxy; b) ZCast 501 core; c) traditional foundry sand mold half with ZCast

core; d) and e) finished casting.

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Z Corporation Z 406 User Manual Page 134