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Appendix I

ZCast Design Guide - 23

Suggested Solutions:

• For the majority of the molds, there should be least a 0.5 in (13 mm) wall thickness

between the metal and the outside of the mold.

CAUTION

Mold wall thicknesses of less than 0.5 inches (13 mm) may allow

molten metal to leak from the mold unexpectedly and cause

personal injury. Design molds to ensure at least 0.5 inches (13

mm) mold wall thickness.

• Around areas of the casting where low porosity is important, or near thick sections in the

casting, there should be vents for gases to escape.

WARNING

Insufficient venting of thick mold sections can result in the

unexpected release of molten metal and personal injury during

metal casting. Design molds with adequate venting capacity and

proper location.

• Vents should be approximately 0.125 in (3.2 mm) in diameter and open to the

atmosphere. The lower limit of vent diameter is 2-3 mm, determined by depowderability.

• Vents DO NOT need to break through to the casting surface. If they pass to within 0.1 in

to 0.2 in (2.5 to 5 mm) from the casting surface, the gas generated inside should

permeate through except in extreme cases.

CAUTION

Vents not located in the core, vents too close to parting lines, or

vents that break through to the casting surface may leak molten

metal and cause personal injury. Locate vents in the core, away

from the casting surface, and as far as possible from parting

lines.

• Insert vents vertically where possible, opening in the cope. Bringing the vents close to

the casting surface runs the risk that the metal will break through, so limiting their

openings to the upper surface of the cope limits the risk of leaking metal.

CAUTION

Vents not located in the cope may unexpectedly leak molten

metal and cause personal injury.

• Mold vents may be designed into the mold and printed or they may be drilled in after

printing. Modifications like these, and the tooling to perform them, are commonplace in

traditional sand casting foundries. It may be the choice of an experienced foundryman to

vent a mold in this manner.