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<p>Inkjet-bonded 3D sand printing technology is becoming a more mature technology. The forming efficiency in the casting is especially important, and the forming efficiency includes printing efficiency, sand mold post-treatment efficiency, and casting forming efficiency. This study investigates the impact of inkjet-based 3D sand printing technology on the productivity of castings. By optimizing the printing parameters—layer thickness, recoating speed, X-resolution, and printhead jetting rate—the efficiency of the printing stage was improved, and predictive models were established for the printing stage, post-processing stage, and casting stage. The study found that layer thickness and recoating speed had a significant influence on printing time, while X-resolution and printhead jetting rate played a secondary role. Additionally, two sand mold designs, truss support structures and honeycomb structures, were introduced to enhance forming efficiency during the casting stage. The model was validated through an engine cylinder block case study, where the optimized parameters improved forming efficiency during the printing stage by 20.17%. The truss and honeycomb sand mold designs improved casting efficiency by 6.96% and 14.18%, respectively. Verification experiments conducted on sixteen printing groups showed that the predictive model for 3D sand casting forming efficiency achieved an accuracy of 94.88%.</p> Graphical Abstract <p></p>

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Improved Forming Efficiency Through the Adjustment of Inkjet-Bonded 3D Printing Parameters and Sand Mold Structure

  • 期刊论文

  • 发表日期：

    2025年1月28日

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  • Jun Zheng,
  • Xiran Qiu,
  • Jun Zhu,
  • Rundong Jia,
  • Bojie Xu,
  • Zhushun Xia,
  • Wei Wang,
  • Wei Ling,
  • Bin Tang,
  • Aizhi Guan,
  • Zhiyi Zhang,
  • Fubin Duan

摘要

Inkjet-bonded 3D sand printing technology is becoming a more mature technology. The forming efficiency in the casting is especially important, and the forming efficiency includes printing efficiency, sand mold post-treatment efficiency, and casting forming efficiency. This study investigates the impact of inkjet-based 3D sand printing technology on the productivity of castings. By optimizing the printing parameters—layer thickness, recoating speed, X-resolution, and printhead jetting rate—the efficiency of the printing stage was improved, and predictive models were established for the printing stage, post-processing stage, and casting stage. The study found that layer thickness and recoating speed had a significant influence on printing time, while X-resolution and printhead jetting rate played a secondary role. Additionally, two sand mold designs, truss support structures and honeycomb structures, were introduced to enhance forming efficiency during the casting stage. The model was validated through an engine cylinder block case study, where the optimized parameters improved forming efficiency during the printing stage by 20.17%. The truss and honeycomb sand mold designs improved casting efficiency by 6.96% and 14.18%, respectively. Verification experiments conducted on sixteen printing groups showed that the predictive model for 3D sand casting forming efficiency achieved an accuracy of 94.88%.

Graphical Abstract