Low-Cost 3D Printing of Cast Iron Using Fused Deposition Modeling

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University of Guelph

Fused deposition modeling (FDM) is an inexpensive metal additive manufacturing technique used for rapid prototyping, batch production, and large-scale manufacturing. This technology is typically used to print thermoplastic filaments and has been adapted to print limited metallic filaments. This study presents novel research into low-cost printing of cast iron using FDM as a potential alternative to the casting process, thus bypassing the lead times and expenses. In this work, sintered cast iron samples presented targeted microstructures for white and ductile cast iron. Sintered cast iron samples achieved a maximum of 92.9% of the standard cast density at 6.69 g/cc and a minimum volumetric shrinkage of 52.18%. Samples across all varied parameters averaged 80% of the standard density at 5.75 g/cc with a sample volumetric shrinkage of 57.82%. This thesis aims to study and analyze printing and sintering process parameters to enhance printed part quality.

Cast Iron, FDM, Additive Manufacturing, Metal AM, 3D Printing, Low-Cost
Drummond M., Eltaggaz A., Deiab I., (2023) �??3D Printing of High Melting Iron Alloys using Metal Fused Deposition Modeling: A Comprehensive Review�?�, The International Journal of Advanced Manufacturing Technology (Accepted).
Drummond M., Eltaggaz A., Nouzil I., Deiab I. (2023), �??Exploration of Printing Parameters for Low-Cost Fused Deposition Modeling (FDM) Printed Cast Iron�?�., 3D Printing and Additive Manufacturing (Accepted)