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<p>Selective laser sintering (SLS) is an additive manufacturing method increasingly used in investment casting to fabricate intricate and precise sacrificial patterns. While this approach allows for complex and accurate shapes, the patterns it produces often have a relatively rough surface, which can affect the smoothness of the final cast component. In this work, the focus was on improving the surface finish of investment cast parts by improving the surface quality of SLS-fabricated patterns made from Primecast (PS101) material. A twisted pillar geometry was fabricated at build orientations from 0° to 90° in 15° steps. Three smoothing techniques were explored: acetone dipping, cold vapour smoothing, and hot vapour smoothing. Hot vapour smoothing proved to be most effective and was further studied using acetone concentrations of 90, 95, and 100%, with exposure times of 3, 7.5, and 15&#xa0;minutes. Statistical testing (ANOVA) confirmed that the process parameters had a significant effect, with strong predictive accuracy. The best results were achieved using hot vapour smoothing with 95% acetone for 7.5&#xa0;minutes. This treatment reduced the surface roughness of the pattern by nearly 40%, and the difference between the smoothed patterns and finished castings was only 4.1%, demonstrating its value in producing consistent, high-quality castings.</p> Graphical Abstract <p></p>

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Improving Surface Quality of Investment Cast Part Using Vapour-Smoothed Additively Manufactured Patterns

  • 期刊论文

  • 发表日期：

    2025年11月9日

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  • Saravanan Kasinathan,
  • Arumaikkannu Ganesan,
  • S. Sasikumar

摘要

Selective laser sintering (SLS) is an additive manufacturing method increasingly used in investment casting to fabricate intricate and precise sacrificial patterns. While this approach allows for complex and accurate shapes, the patterns it produces often have a relatively rough surface, which can affect the smoothness of the final cast component. In this work, the focus was on improving the surface finish of investment cast parts by improving the surface quality of SLS-fabricated patterns made from Primecast (PS101) material. A twisted pillar geometry was fabricated at build orientations from 0° to 90° in 15° steps. Three smoothing techniques were explored: acetone dipping, cold vapour smoothing, and hot vapour smoothing. Hot vapour smoothing proved to be most effective and was further studied using acetone concentrations of 90, 95, and 100%, with exposure times of 3, 7.5, and 15 minutes. Statistical testing (ANOVA) confirmed that the process parameters had a significant effect, with strong predictive accuracy. The best results were achieved using hot vapour smoothing with 95% acetone for 7.5 minutes. This treatment reduced the surface roughness of the pattern by nearly 40%, and the difference between the smoothed patterns and finished castings was only 4.1%, demonstrating its value in producing consistent, high-quality castings.

Graphical Abstract