How to 3D Print Sustainable Sacrificial Tooling for Composite Part Production and All-New Designs

March 25, 2020

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Hollow Composite Fiber Parts Created with 3D Printed Sacrificial Tooling that Washes Out With Tap Water, from ExOne

With today's focus on lightweighting, hollow parts made with composites, such as ducting, fuel tanks, mandrels, and rocket shrouds, are in higher demand than ever before. Manufacturing these parts is also now easier than ever with a new water-washout tooling solution being used by Sikorsky and others. Learn how binder jet 3D printing can produce durable, accurate sacrificial tools in sand - using a binder that remains water-soluble throughout process. These tools are highly resistant to thermal expansion and can simply be washed out with water after autoclaving. What's more, the sand can also be reclaimed for sustainable reuse.

Primary Topics:

  • How washout tooling is created and why it’s so simple
  • Why binder jet 3D printing is ideal for making tooling
  • Process specifications, tooling tolerances and sustainable properties
  • All-new design possibilities with 3D printed tooling

Rick Lucas
Chief Technology Officer, ExOne
Rick Lucas has served as ExOne's Chief Technology Officer since 2012. He is responsible for R&D and manages the New Markets Group. Previously, Lucas served in leadership positions at Touchstone Research Laboratory and Lake Shore Cryotronics. With more than 25 years of experience, Lucas has set up operations for more than 20 advanced material products, including four R&D 100 award winners. He serves on the governance board for America Makes and the Materials Processing Equipment Technical Advisory Committee for the U.S. Department of Commerce. He holds an AAS in Manufacturing Technology, a BA in Physics, and an MBA.