3D printed foundry hollowware - step change improvement to metal casting

Metal components are required across many sectors including aerospace, automotive, manufacturing and construction. As such, cast metals in the UK generated sales of £1.89bn in 2017 (Cast Metals Foundation, Industry Census) with a global market of £123Bn in 2019 (Grandview Research, 2020). Liquid metal is cast into different and often specific shapes. Foundries use specialised ceramic hollowware (pipes, bends, funnels, downsprues) to construct paths, along which liquid metal flows. However, there are less than 10 manufacturers globally. Nearly all are heavier than needed, which means that metal cools rapidly as it flows through them. Foundries must therefore heat metal hotter than it would otherwise need to be, wasting energy.

CAT International Ltd, a leading manufacturer of foundry filters and consumables, have developed a novel ceramic formulation (covered by a patent) and process that they now wish to apply to hollowware for use in the metal casting foundry sector (foundation industry). We will use Additive Manufacturing (3D printing) processes and proprietary ceramic formulation (ceramic materials combined with organic resin) that we have already developed to fabricate hollowware. We have undertaken initial work and seek to carry our further industrial research to optimise post treatment processes.

By using our new innovative process, we seek to enhance performance throughout the supply chain. We will minimise materials wastage (scrappage and repair) associated with defective castings due to sub-optimal hollowware. We will allow foundries to pour at lower temperatures, reducing energy consumption. We will enable robust supply chains for a critical consumable, where we produce hollowware for foundries.

Changes to the sector as a result of supply chain disruption and high energy prices, made worse by the Russia-Ukraine war give us impetus to drive efficiencies, in line with UK and global priorities to reduce waste and work towards net zero emissions by 2050\.