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Appendix I
ZCast Design Guide - 10
5.2.3
Combination Method
Combining ZCast with the traditional sand casting techniques can keep the cost per prototype
down to a minimum. Mold sections (cores in particular) are made in ZCast while the rest of the
mold is made conventionally. In the combination method, foundry sand is packed around a
pattern. The pattern can be machined from a variety of materials or the pattern can be printed on
a Z Corp. 3D Printer. If printed, the patterns would be made with one of the Z Corporation plaster
based materials (zp100 series), infiltrated with an epoxy and mounted to a board. A zp100 series
pattern can be used multiple times.
This method requires an intimate understanding of the design of conventional sand molds. ZCast
mold components used in the Combination Method are subject to most of the same restrictions
that apply to conventional mold components. The advantage to using ZCast in this case is that
cores and inserts can be made without any special tooling (e.g. core boxes) that would lengthen
the time to produce the first casting.
A further enhancement of the sand-casting process applies to both the Shell-Cast and
Combination Methods. One can fabricate conventional patterns using ZCorp materials; most
preferably with zp100-series plaster-based materials as shown below
1
.
5.3 Designing Molds in your CAD System
Regardless of the method you select, it’s likely that some CAD work will be required. It is
necessary to create the most accurate representation of your design digitally, as it will be
represented in the real world from a 3D print.
1
For step-by-step guide on this topic, contact your Z Corp. account representative.
a b
d e
Figure 5: Combination Method – a) zp102 patterns infiltrated and backed with
epoxy; b) ZCast500 core; c) traditional foundry sand mold half with ZCast
core; d) and e) finished casting.
c