Digital modeling of metamaterials for 3D printing of foundry patterns in the context of transition to on-demand manufacturing

Abstract

In today's conditions of global instability, market fluctuations and variability of consumer needs, manufacturing "on demand" is becoming a promising strategy, supported by innovations in the field of additive manufacturing (3D printing). The purpose of the work is to study the use of the sphereneRHINO program (Spherene Inc., Switzerland) for designing and printing porous structures of foundry models instead of traditional ones made of expanded polystyrene. Methodology: the process of digital design of polymer patterns was analyzed, design was performed in the specified program and pattern samples were printed. Findings. The algorithm and capabilities of the sphereneRHINO program are exemplarily described, samples of cellular material of patterns were obtained, a method of printing them with open pores and transit porosity was developed. The gas permeability of the pattern was used to vacuum the sand mold and the pattern structure, which allowed it to be gasified with molten metal with simultaneous pumping out of gases and to create the effect of casting by vacuum suction. Originality. The foam material, which was not intended for casting patterns, was used to design and print porous patterns with control of density, wall thickness and geometry of printed pores. Practical value: a significant reduction in the design and manufacturing time of polymer patterns through the use of 3D printing contributes to the adaptability of enterprises to market changes, the implementation of the "on-demand" production model and the digitalization of the casting process with the minimization of time and resource costs.