The ZCast Direct Metal Casting process provides the ability to produce cast metal parts from a CAD file significantly faster and less expensively than traditional prototype casting methods. The process involves printing molds and cores on a 3D Printer directly from digital data, eliminating the pattern and core box production step in the traditional sand casting process. Metal is then poured into the 3D printed molds. The technology allows engineers to prototype parts in metal that were previously cost and time prohibitive.The ZCast Process guarantees:
Extremely fast turnaround from CAD file to prototype metal part
Ability to print complex molds and cores
In-house mold making capabilities for product manufacturers
Simple metal pouring process for foundries
FREQUENTLY ASKED QUESTIONS ABOUT ZCAST
What is the ZCast process?
The ZCast process involves directly casting metals in molds printed on Z Corporation’s line of 3D Printers. We are offering the ability to directly print the mold cavity or mold inserts. Traditionally, these molds need to be created by first producing a pattern (or pattern set) which would then be used to create the molds. In the case of sand casting, a set of patterns is used to create the impressions in the sand. In the case of investment casting, wax patterns are needed to then create a ceramic mold. With the ZCast process, we are offering the option to skip the pattern step.
What are the advantages of the ZCast process?
The production of prototype castings using conventional methods often can take several weeks and be prohibitively expensive. These constraints often limit the number or preclude the production of metal prototypes during the development process. The ZCast process can offer the opportunity to significantly reduce the time required to obtain metal castings while also reducing the cost. Specific time and cost savings will depend on the size and complexity of the desired part, but can be substantial for many customer needs. For many parts, castings can be produced in as little as 1-2 days. The ZCast process also provides the freedom to produce more complex castings that previously were difficult to produce using conventional tooling methods. We recommend that the customer talk directly to Z Corp. and its partners to evaluate how this process may help them.
What are the new molds made of? Are they ceramic?
ZCast powder is a blend of foundry sand, plaster and other additives suitable for casting low temperature metals.
What metals can be cast?
ZCast 500 is a powder of set that allows casting of aluminum and other lower temperature metals like zinc and magnesium.
Will this capability be available on all Z Corp. machines?
The material is available for all of Z Corporation’s current systems, the ZPrinter 310, Spectrum Z510 and Z810 Systems.
Will this capability be available on all Z Corp. machines?
The Z810 Printer requires an upgraded material feeder that has been designed for ZCast powder. The ZPrinter 310 and Spectrum Z510 can be used unmodified. Consult your Z Corporation sales representative for details on upgrade pricing.
What is the tolerance and surface finish that can be achieved with the ZCast process?
Customer parts produced have yield results that mimic traditional sand casting finishes and tolerances.
Can I machine the castings produced?
Yes. The cast metal part will have similar metallurgical characteristics as metal parts made using conventional casting methods.
