Application of fusion deposition modelling for rapid investment casting – a review

The rapid prototyping technologies are being used in the various fields of engineering. The ability of producing very small and intricate details makes the rapid prototyping technologies suitable for making patterns for investment casting. Moreover, by using rapid prototyping technologies the patterns can be produced without the necessity of costly hard tooling. The rapid prototyping technologies are considered very useful when only limited numbers of pieces are promptly required as in making prototypes, design iterations and design optimisations. The fusion deposition modelling (FDM) is a rapid prototyping technology that can use a number of materials which can be effectively used for making patterns for investment casting. Different non-wax materials are available which can be used for making patterns and can be burnt easily during autoclaving/firing. This paper reviews the suitability of FDM for making patterns for investment casting. The direct and indirect methods of producing casting patterns along with different approaches have been discussed. Different available FDM materials and their properties have been presented. The pattern accuracy depends upon a number of FDM process parameters. Various process parameters have been identified to obtain the desirable dimensional accuracy and surface finish of the casting patterns.