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.