Lost Wax Casting of Turbine Blades

Companies in the aerospace industry utilize standard methods for obtaining parts through lost wax casting by using traditional injection molds. This traditional process is time-consuming and expensive and does not allow for part designs with complex geometries.

CONTEXT & CHALLENGE

Obtaining a reactor turbine made with the lost-wax method:

• A plaster/ceramic shell mold is formed around the printed part.
• The mold is fired in a furnace to melt away the wax, leaving a cavity in the shape of the part
• Molten metal is poured into the mold to cast the part

Additive manufacturing technologies now make it possible to design a master model with complex geometries or aerodynamic properties which were impossible to manufacture with traditional methods. In addition, they optimize the weight of each part (an essential element in production for the aerospace industry).

SOLUTION DEPLOYED

• DLP MOVINGLight® 3D printers
• PLASTCure ABS3650 material

BENEFITS

Thanks to DLP MOVINGLight® 3D printing technology and PLASTCure ABS3650 material, the master model for lost wax process has been optimized for:

• A more complex geometry of the master model for improving the aerodynamic properties of the part
• A reduction in the weight of the final part with a significant improvement in the efficiency of the turbine blade
• A surface finish and dimensional accuracy maximized
• A better flexibility to modify the master model