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Digital Manufacturing of One-Off Replacement Components Using Reverse Engineering and Rapid Low-Pressure Sand Casting: Dimensional Evaluation and Key Challenges

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Abstract:

Remanufacturing by casting of end-of-life (EoL) components can be challenging as it requires specific molds/cores, machinery and tooling. The use of 3D scanning technology and rapid casting processes can produce high-quality, efficient components. However, error propagation during the manufacturing process can significantly affect the dimensional accuracy of the final product. In this study, the dimensions of a case study part were evaluated at the main stages of the rapid hybrid low-pressure sand casting (LPSC) process, from the initial CAD model to the final casting, to identify the main causes of final 3D surface deviation. The casting design was optimized using coupled thermal and fluid-flow FE computations for two suitable casting orientations: horizontal (H) and vertical (V). After the 3D sand-mold printing process, an optical 3D scanner was used to extract surface data from each printed mold part. 3D surface deviations caused by the printing process were evaluated by comparing the individual mold components to their original CAD models using GOM Inspect Pro® software. The final castings were also compared to the initial CAD models for both orientations to quantify the overall 3D surface deviations resulting from the rapid LPSC process chain, including 3D printing, liquid metal shrinkage and contraction during solidification and cooling. The results provide a foundation for improving dimensional accuracy of one-off replacement components produced by the hybrid LPSC process.

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Periodical:

Materials Science Forum (Volume 1188)

Pages:

75-83

Online since:

April 2026

Authors:

Ahmed Ktari*, Davis Lu, Griffin Ainsworth, Mohamed El Mansori

Keywords:

3D Scanning, 3D Surface Deviation, Remanufacturing by Casting, Reverse Engineering, Sand-Mold Printing

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Creative Commons CC BY 4.0

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* - Corresponding Author

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