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Hybrid Additive/Substraction Method for Rapid Casting Prototypings with Light-Cured Sand

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2016 ASEE Annual Conference & Exposition


New Orleans, Louisiana

Publication Date

June 26, 2016

Start Date

June 26, 2016

End Date

August 28, 2016





Conference Session

Additive Manufacturing Education

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Paper Authors


Pavel Ikonomov Western Michigan University

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Associate Professor of Engineering, Design, Manufacturing, and Management Systems, has been working on Virtual Reality simulation for more than 25 years. His main focus has been 3-D modeling design and VR simulation in manufacturing and assembly, medical application, large scale dynamic simulation in various research organizations in Japan like Hokkaido University, TMIT and 3D Incorporated and Virtual Reality Center Yokohama (CTO), UCLA (2001-3) and NIST (2002-3). At NIST he was responsible for industrial Virtual Reality Assembly (VADE) and worked with VR simulation for the optical nano-tweezers. Dr. Ikonomov will oversee the development of VR lab simulation part. Dr. Ikonomov has more than 120 journal and refereed conference proceedings publications, three books and book chapter.

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Jorge Rodriguez P.E. Western Michigan University

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Faculty member in the Department of Engineering Design, Manufacturing, and Management Systems (EDMMS) at Western Michigan University's (WMU). Co-Director of the Center for Integrated Design (CID), and currently the college representative to the President’s University-wide Sustainability Committee at WMU. Received his Ph.D. in Mechanical Engineering-Design from University of Wisconsin-Madison and received an MBA from Rutgers University. His B.S. degree was in Mechanical and Electrical Engineering at Monterrey Tech (ITESM-Monterrey Campus). Teaches courses in CAD/CAE, Mechanical Design, Finite Element Method and Optimization. His interest are in the area of product development, topology optimization, additive manufacturing, sustainable design, and biomechanics.

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Developments in rapid casting technologies have led to a new era of inclusion of 3D printing. Rapid prototyping provides the flexibility and ease of reproducing a sand mold directly from CAD models, eliminating patterning steps, thus reducing the process time for creating prototypes. A novel hybrid technique, utilizing both additive and subtractive manufacturing techniques, has been developed and implemented. This technique finds applications in production of shaped cavities/molds for casted metallic parts for various rapid prototyping and rapid manufacturing application. The proposed concept of simultaneous building and machining of carbon shell sand molds for rapid prototyping (RP) of functional castings utilizes a combination of two RP techniques to eliminate the limitations of both. The proposed new hybrid RP technique based on previous research for developing of novel RP Infrared Light Sintering (IRS) and Machineable Mold Material (MMM) machining technologies. The IRS RP technique is used to build the molds layer by layer from 3D CAD models. The Machineable Mold Material process will be utilized in machining of each layer before the next layer is built. The hybrid approach will combine the advantages of both methods to produce RP parts, quickly with high precision and surface finish. The extrusion system for the machineable mold material, machining parameters, and suitable machining tools has be tested and optimized. The outcome of this research will be the ability to produce functional casting prototypes of any size, complexity, and metal that could be mechanically and physically field tested and used as actual parts. To enhance practical research and learning experience of the students applying this hybrid technology, several undergraduate projects, master and Ph.D. allowed student to participate actively in the development of the processes. Numerous research presentation, papers and thesis was produced.

Ikonomov, P., & Rodriguez, J. (2016, June), Hybrid Additive/Substraction Method for Rapid Casting Prototypings with Light-Cured Sand Paper presented at 2016 ASEE Annual Conference & Exposition, New Orleans, Louisiana. 10.18260/p.25501

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