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When the Hazleton Casting Company contracted with a company that was developing four different parts, the customer asked to test four design configurations for each of them. That’s 16 unique castings, all with complex geometries that would normally require patterns and/or core boxes (and the time, skill and effort that goes into making these).

But this tooling wasn’t necessary. HCC instead used a sand 3D printing system to print the molds and cores directly, reducing lead time and avoiding that tooling expense. You can read the full story in the November issue of Additive Manufacturing magazine.

Also in this issue:

• A newly developed metal matrix composite (MMC) is extending the range of applications for MMCs into highly complex, lightweight forms that could only be made additively.
• A 3D-printed medical drill incorporates conformal cooling lines that feed coolant along the helix and back to the toolholder, protecting bone from heat damage (and coolant contamination) during surgery.
• A research project pairs polymer 3D printing with investment casting to create a lightweight airplane seat frame with an organic appearance.

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