As a relatively novel production method, additive manufacturing (AM) offers new possibilities in design area owing to the ease of production. Free form fabrication, including parts permits the formation of strong, also light weight structures with complex geometry, which is much more difficult using conventional manufacturing techniques. Binder Jetting as one of the AM Technologies presents the fabrication of parts layer by layer with the help of gypsum and binder in liquid droplets form. Although Binder Jetting is not a direct metal part production method, molds used in conventional casting may be produced by this method. This study focused on the investigation and limit of design parameters to generate complex molds using Binder Jetting. During this study, different lattice structure have been designed as a function of size, cell dimension and void dimension. Three different runner systems were designed in order to completely fill the molds produced with Binder Jetting by casting. AlSi9Cu3Fe1 alloy was cast into the molds. The in-mold-design was found to have a direct effect on the complete filling of the mold. The relationship between the design complexity and design freedom of the lattice structures to be produced by the conventional casting method were examined. It was observed that the success of removing non-adhered gypsum powders in the mold before casting depended on the design parameters of the lattice structures.
Anahtar Kelimeler: additive manufacturing, binder jetting technology, design freedom, complexity, lattice structure