Z Corporation 406 User Manual

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Z Corporation 406 User Manual Manual pdf 128 page image

Appendix IZCast Design Guide - 103 ZCast AdvantagesToday, metal casting molds are commonly created by first producing a machined pattern (orpattern set) that is then used to create the molds. Instead of utilizing this costly and often timeconsuming process, the ZCast process utilizes 3D printing to create the molds and mold insertsdirectly from CAD data. With the ZCast process, Z Corp. provides the option to skip the patternor tooling step, significantly reducing the time required to obtain metal castings, while alsoreducing the cost.The production of prototype castings using conventional methods can often take several weeksand be prohibitively expensive. These constraints limit the number or preclude the production ofmetal prototypes during the development process. Specific time and cost savings will depend onthe size and complexity of the desired part, but can also be substantial for most customer needs.Castings can be produced in as few as one or two days for a fraction of the cost of traditionaltooling.3.1 The MaterialZCast 501 powder is a plaster-ceramic composite suitable for casting low temperature metals(aluminum, magnesium, and zinc). Tests conducted by Z Corp. and it’s foundry partner (GriffinIndustries) have shown results that mimic traditional sand casting finishes and tolerances. Manysuccessful castings have been made in 356, 390 and 319 aluminum as well as zinc, bronze, andmagnesium.The ZCast material set can be used on the Z810 Large Format 3D Printer, the Z406 3D Printerand the ZPrinter ® 3D Printer.WARNINGDo not use ZCast 501 molds with molten ferrous metals orother metals with pouring temperatures above 1100 o C(2000 o F). The molds can suddenly fail unexpectedlyreleasing entrapped gases and molten metal causingserious personal injury.3.2 Design FreedomIn addition to reducing the time and cost to create a prototype casting, the ZCast process alsoprovides the freedom to produce complex castings that previously were difficult or impossible toproduce using conventional tooling methods. One of the powerful features of the ZCast processis the freedom to incorporate undercuts and channels in the molds. Runners and vents can beformed inside the mold that are otherwise impossible to machine; cores can be integrated into themold, minimizing the number of parts and simplifying setup. For prototype parts, this greatlysimplifies the mold design process.Design alternatives include:• The Direct Pour Method involves printing an entire mold, cores and all, in the ZCastmaterial. This usually uses the most material, but allows for virtually no set-up time andvery quick production of your prototype casting.• The Shell Method involves printing only a thin (½ inch thick) mold to surround the entirepart. This shell is then backed with traditional foundry sand in a flask to create a moldsuitable for pouring. This helps to minimize the amount of ZCast material used and is