Casting of complex structures in aluminum using gypsum molds produced via binder jetting

Purpose: The purpose of present paper is to enlarge the knowledge about the performance of gypsum powder to realize complex molds or cores for aluminum casting. Design/methodology/approach: The research was divided into two activities: simple; and complex-part production capability. In the simple-part step, the performance of gypsum powder and the minimum mold thickness that would withstand the casting process. In the complex-part step, the authors first investigated the powder removability as a function of geometry complexity and then binder jetting performance was evaluated for the case of lattice-structure fabrication. Findings: All the geometries tested withstand the casting process demonstrating the benefits in terms of complexity part design; however, the process suffers of all the typical defect of casting as misrun, porosity and cold shut. Originality/value: The results found in this research improve the benefits related to additive manufacturing application in industrial environment and in particular to the binder jetting technology and the rapid casting approach.