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3.0 Metal Casting
3.1 Direct Metal Casting
The ZCast 501 Direct Metal Casting process provides the ability to produce cast metal parts
from a CAD file significantly faster and less expensively than traditional prototype casting
methods. Printing molds and cores directly from digital data eliminates the pattern and core
box production step used in traditional sand-casting processes. Metal is poured directly into
the 3D printed molds. The technology allows engineers to prototype parts in metal that are
costly and time consuming to produce using traditional methods.
Direct Casting Material can be used to create sand casting molds for non-ferrous metals. This
material is a blend of foundry sand, plaster, and other additives that have been combined to
provide strong molds with good surface finish. It is designed to withstand the heat required
to cast non-ferrous metals.
After removal from the printer, printed molds must be baked in an oven at 375°F for 4-8
hours to remove excess moisture from the mold before metal is poured. ZCast 501 molds
should never be infiltrated. Common foundry products such as core paste and refactory
mold wash can be used to prepare the mold for pour as they have been designed to
withstand the temperatures of the casting process. Refer to the ZCast Design Guide for more
details on this process.
the ZCast process:
• Extremely fast turnaround from CAD
file to prototype metal part
• Easily print complex molds and cores
• In-house mold-making capabilities for
product manufacturers
• Simple metal-pouring process for
foundries
Tech Tip
Investment casting: Work with your local
investment casting foundry to find the
proper shrinkage factor for the metal
alloy used for the pour.
Investment casting materials
Category Description Unit of Measure Part #
Powder zp 14 pail 11 lbs. (5 kg) 06127
zp 14 drum 44 lbs. (20kg) 06128
Binder zb 51 1 gal. (3.8 l) 05802
Infiltrant Z-Bond 11 7.76 oz. (220 g) 15079
Infiltrant Paraplast X-TRA 17.6 lbs. (8 kg) 10434
Direct Metal Casting Materials
Category Description Unit of Measure Part #
Powder ZCast
501
pail
33 lbs. (15 kg) 06439
ZCast
501
drum
132 lbs. (60 kg) 06438
Binder zb 56 clear 1 gal. (3.8 l) 06312
Figure 13: Metal Casting
3.2 Investment Casting
zp 14 Investment Casting Material can be used to quickly fabricate parts that can be dipped
in wax to produce investment casting patterns. The material consists of a mix of cellulose,
specialty fibers, and other additives that combine to provide an accurate part while
maximizing the absorption of wax and minimizing residue during the burn-out process.
For prototyping metal parts, investment casting is possible using zp 14. The process involves
printing a male pattern which is then infiltrated with wax and/or Z-Bond 11. Once infiltrated,
the pattern is coated with an investment slurry, creating a mold. A cycle in the oven will burn
out the printed pattern.
(99 pages)
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