The focus of PERFECT-3D is ceramic additive manufacturing to create rapid tooling in support of investment castings. The primary product families are ceramic cores, molds, and filters.
PERFECT-3D Most Common Product Families
Cores – Ceramic 3D-printing addresses the complexity of new core designs that surpass the capability of injection molding. In addition, 3D-printing provides a cost-effective means to make a small quantity of cores needed during casting development.
Molds – Ceramic 3D-printing can handle the new casting designs that challenge the traditional ceramic dipping associated with wax patterns. As importantly, the 3D-printing of ceramics provides ready-to-pour molds that enable “skipping the queue” at the foundry.
Filters – Ceramic 3D-printing provides a consistent flow system and material cleanliness that is not achievable with conventional filters. In addition, 3D-printed filters avoid the introduction of inclusions that are very common with traditional foam filters.
The PERFECT-3D approach is based on leveraging additive manufacturing (AM) to create tooling for the rapid production of parts. PERFECT-3D also provides other custom 3D-printed solutions for industrial customers.
Business Benefits by Product Family
While 3D-printing of ceramics is still in its relative infancy, it has the potential to reduce tooling costs for complex precision castings by more than 70%, and it can provide 80% reduction in the lead time for cores and molds compared to conventional processes.
PERFECT-3D and Process Overview
The clickable image below is a summary 3-minute video that provides an overview of the PERFECT-3D manufacturing process.