User manual

Appendix I
ZCast Design Guide - 17
9. Add mating features to help align the mold components. These can be simple holes
pegged with dowel pins, or mating positive and negative features built into the model.
10. Add venting to the mold cavity and to the cores.
11. Add flanges or seats for prefabricated pouring cups (if utilized – direct pour only).
12. (optional) Lighten mold pieces by cutting out material from heavy mold sections (direct
pour only), or shell the entire mold to approximately 0.5 to 0.75 in (13 to 19mm) (Shell
method only).
13. Add mating surface offsets to facilitate assembly of components.
14. Divide the mold components into sections suitable enough to print in your Z Corp. 3D
Printer (Typically Shell method only).
WARNING
Inadequate venting in the mold or core can lead to the
unexpected release of entrapped gases and molten metal
causing personal injury during metal casting. Venting paths
in the mold must be arranged and directed away from the
metal path to avoid entrapment of gases.
5.3.2 Shell Method
If you plan to use the Shell method you will need to:
1. Begin with steps one through five from the Direct Pour method.
2. Divide out the core geometry (if a core or cores exist in your design) and add core prints
3. Isolate the casting surfaces of your part to be cast and divide it into desired number of
sections.
4. Shell each of the resulting open surface sections.
5. Design gating system on a separate conventional pattern.
6. Incorporate alignment features into shell and patterns.
7. Incorporate locking features so that shells are firmly held into place by foundry sand.