Research on key technique of line forming for 3D sand mould printing based on quantitative analysis of binder content

Purpose The purpose of this study is to analyse the problem of high binder content in sand mould and to solve it. Meanwhile, to increase build speed, especially for heavy casting’s sand mould with a high value in layer height, such as 2 mm in construction instead of the industry standard of 0.3 mm, line forming for three-dimensional (3D) sand mould printing is researched. Design/methodology/approach Brief introduction of 3D sand mould printing and key issues are given first. Then, this paper quantitatively analyses binder content in sand mould. Finally, to acquire sand mould with appropriate binder content and high build speed, line forming combining traditional furan no-bake sand manufacture technique is researched, as well as relevant feasible schemes and current progress. Findings The study shows that compared with traditional technique, binder content in sand mould produced by available 3D printing technique is too high, bad for sand mould’s properties and quality of castings, while line forming brings guaranteed binder content and improved build speed. Research limitations/implications More experiments are needed to demonstrate quantitative analysis of binder content and to obtain flowability of moist sand, detailed structure design of nozzle and practical build speed, as well as methods of circulation of materials considering solidification time. Practical implications Line forming with higher build speed and suitable binder content means excellent properties of sand mould and castings as well, bringing obvious implication for moulds industries and manufacturing industry. Originality/value This new method could increase build speed and meanwhile guarantee binder content. Thus, its application prospect is promising.