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Analysis of fused filament fabrication / fused deposiotion modelling applications for production of casting patterns used in sand casting

Bernat Łukasz, Kroma Arkadiusz

Advances in Science and Technology. Research Journal

2025

Vol. 19, no. 7

427--439

This paper presents an analysis of FFF/FDM (Fused Filament Fabrication / Fused Deposiotion Modeling) applications for production of casting patterns used in sand casting, with particular emphasis on short-run and prototype production. For this purpose, casting patterns of different shape and height of incremental layer (0.29 mm, 0.19 mm, 0.14 mm and 0.09 mm) were made of Z-ABS filament produced by Zortrax. Geometrical and dimensional analysis of the patterns was carried out, surface roughness parameters were measured, and a visual analysis of the surface was performed. In order to evaluate the conclusions observed based on the analysis of casting patterns, 130 x 102.5 x 37.5 mm sized shaped castings were designed and manufactured from aluminum and grey cast iron, which were also subjected to analysis. The last element of the research was a visual analysis of the reproduction of markings on the castings.