CAT International Limited - Development of 3D printing machine for carbon and carbon composite articles

The problem with producing high purity single crystal (SX) materials is that contaminants and
defects present in the casting mix, oxidation, and contamination from the crucible, or by
simply not using filters at all results in low yield production. Structural defects or grain
boundaries are introduced, and the advantageous mechanical, oxidative and heat resistant
properties essential for high end applications are lost.
To solve SX low yield production, which costs foundries scrap losses as high as 40% ($110
m) a year, we aim to provide a low cost, high yield production technology of manufacturing
aids, carbon composite filtration devices, which can be produced in a SME viable commercial
3D printer. Ultimately, the proposed 3D printer will be printing filters for production
purposes. The new filters will allow smaller scale filters, with greater control over porosity,
surface area and extraction efficacy, allowing higher yield SXs to be produced for the first
time.
The main project printing innovation is the creation of the ceramic and carbon precursors and
the delivery of the precursor through a novel print head. This will enable a new 4th class of
3D printing, not previously possible since the birth of 3D printers in the early 1970’s. The
prototype high purity metal filtration device will be an improvement over the standard article,
essential across all metal casting industries processes. We will further create enhanced
degassing rotors from the SX materials, essential to all aluminium pours for enhanced yield.
Although SX alloys account for only 0.02% of the total high performance steel market, their $
value per tonne is 46 x greater for high performance alloys compared to crude steel (0014 cf
0.06, Roskill).
The 3D printing process can be adapted to generate rapid prototyping and further
manufacturing aids that will lead to novel, new technology