Case Studies

3D Printed Foundry Filters

3D Printed Foundry Filters

3D printed foundry filters may be the answer the industry has been looking for. These industrial products whether they be Ceramic foam filters, made of; alumina filters or alumina foam filters and indeed zirconia ceramic filters are regularly used in the investment casting industry to improve the casting quality. Such products are designed for the removal of any impurities in the molten metals being poured through. In doing so there is less likely need to grind or machine casted parts afterwards.

These traditional processes are limiting due to the restrictions they have on manufacturing complex structures and in creating deliberate geometrical shapes to increase their performance. For may years the industry has looked for ways to enhance their performance.

Using 3D printed industrial filters allows for designs which optimise;

  • pre-determined and designed passages to increase contamination capture
  • design structure (PPI) for repeatable and predictable flow rates to remove variation in the casting process
  • structure which won’t break down during metal flow preventing contamination
  • design structure to optimise filter output and therefore maintains a smooth laminar flow

Now it is possible to get 99% dense ceramic parts by using a 3D printers

Avignon Ceramics is using 3D Printed Foundry Filters to produce a more efficient filters. In the field of foundry, ceramics are an excellent choice to produce consumable tools, including ceramic filters. Ceramics are the only materials that are both high temperature resistant and chemically stable.

Ceramic filters

Traditionally

Traditional processes only allow for randomly obtained structure. Meanwhile 3D Printed Foundry Filters allow engineers to design a tailor made and hollow part. Favorites include gyroid or geometric designs. Detailing the structure, size and pore size of the filter. Therefore, 3D printing technology enables more control of the casting and the accuracy of the filtration.

Molten metal

Ceramic foams where used to filter molten metal. Ceramic foam filters made of, alumina filters or alumina foam filters and indeed zirconia ceramic filters are regularly used in the investment casting industry to improve the casting quality .Indeed, traditional processes such as moulding or injecting can’t manufacture ceramic foams. So a traditional ceramic foam is made when a polymer structure is coated in a ceramic slurry. Then, by sintering the ceramic the polymer structure disappears and only the ceramic foam remains. This is because hollow structure are impossible to obtain with these processes.

Avignon Ceramics produces ceramic parts for foundry, aerospace and energy industries. The company is historically an  expert on ceramic injection molding and produces cutting edge parts such as aerospace cores.  

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