Production of a sample automotive part by integration of rapid prototyping and a precision casting process

Abstract

The goal in the manufacturing arena is to present new products from concept to market quickly and inexpensively. Introducing new products at ever increasing rates is very critical for remaining succesful in a competitive global economy. To integrate all prototyping, manufacturing and optimizing studies in order to decrease the product development cycle time is one of the major concerns of all engineering fields. In the present study, plaster mold casting process is chosen as the precision casting method for prototyping and manufacturing of a sample automative part. This process is first examined using Taguchi and mixture design of experiments to optimize some of its process parameters. Experimental results show that the cycle time can be decreased by increasing temperature and mixing time. Some industrial waste products such as fly ash and polymer additives can be used for stabilizing the molding process and increasing the surface quality of the castings.