User manual

Appendix I

ZCast Design Guide - 15

Figure 4: Shell Method – ZCast components of a shell mold (left).

Assembled mold with ZCast components packed in foundry sand. Note

that the risers, runners and sprue have been formed in the foundry

sand (right).

5.2.3 Combination Method

Combining ZCast with the traditional sand casting techniques can keep the cost per prototype

down to a minimum. Mold sections (cores in particular) are made in ZCast while the rest of the

mold is made conventionally. In the combination method, foundry sand is packed around a

pattern. The pattern can be machined from a variety of materials or the pattern can be printed on

a Z Corp. 3D Printer. If printed, the patterns would be made with one of the Z Corp. plaster

based materials (zp100 series), infiltrated with an epoxy and mounted to a board. A zp100 series

pattern can be used multiple times.

This method requires an intimate understanding of the design of conventional sand molds. ZCast

mold components used in the Combination method are subject to most of the same restrictions

that apply to conventional mold components. The advantage to using ZCast in this case is that

cores and inserts can be made without any special tooling (e.g. core boxes) that would lengthen

the time to produce the first casting.

A further enhancement of the sand casting process applies to both the Shell Cast and

Combination methods. One can fabricate conventional patterns using Z Corp. materials; most

preferably with zp100-series plaster-based materials as shown below

CAUTION

Use only ZCast 501 material for the mold sections and cores

for the Combination Method casting technique. Other mold

materials can unexpectedly release molten metal and cause

personal injury during metal casting.

For step-by-step guide on this topic, contact your Z Corp. account representative.