Laser Sintering (LS) in a layer manufacturing technique and currently it is extensively used to produce concept models, functional parts, and also patterns for investment casting (IC). CastForm ™ Polystyrene(CF) is a powdered material used for fabrication of IC patterns employing the LS process. The use of the CF material is one of the fastest and most cast effective Rapid Manufacturing (RM) routes to produce small quantity wax-like patterns for shell or flask IC. The manufacture of CF casting patterns constitutes two stages. The first is the building of a "green" part and second is its infiltration with wax. The accuracy of the patterns, and ultimately the final accuracy of the metal castings, is determined by the CF material properties and the applied process parameters. The factors affecting the accuracy of the CF patterns are investigated in this paper. In addition, different ways to improve the process accuracy are discussed. An analysis of advantages and limitations of this RM technique for IC patterns fabrication is provided.
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