https://sam.ensam.eu:443 The DSpace digital repository system captures, stores, indexes, preserves, and distributes digital research material. Fri, 15 May 2026 02:36:28 GMT 2026-05-15T02:36:28Z http://hdl.handle.net/10985/23606 Reduced consumption of materials and hazardous chemicals for energy efficient production of metal parts through 3D printing of sand molds SIVARUPAN, Tharmalingam; UPADHYAY, Meet; ALI, Yahia; EL MANSORI, Mohamed; DARGUSCH, Matthew S. Metals remain essential structural materials for many demanding engineering applications requiring high strength at elevated temperatures and good performance in environments subjected to high thermal fluctuations such as often encountered in the automotive, rail and aircraft industries. The sand-casting process is one of the most preferred methods of producing complex and intricate shaped components out of metals with good strength at elevated temperatures. Unfortunately, the sand casting process also leads to the direct and indirect production of carbon dioxide. Three-dimensional sand mold printing has been revolutionizing traditional production methods by reducing the unnecessary consumption of metal and chemicals when manufacturing a part through sand casting. This paper explores the opportunities that are emerging in the area of 3D printing of sand molds and the positive impact that these new technologies and practices are having on the environmental impact of current sand-casting processes. The paper demonstrates that 3D printing of sand molds enables new manufacturing strategies reducing the direct CO2 emissions and reducing the amount of metal required by enabling design optimization of both the component and mold/core assembly. Further benefits will be realized through the development of environmentally friendly binder systems. Mon, 01 Jul 2019 00:00:00 GMT http://hdl.handle.net/10985/23606 2019-07-01T00:00:00Z SIVARUPAN, Tharmalingam UPADHYAY, Meet ALI, Yahia EL MANSORI, Mohamed DARGUSCH, Matthew S. Metals remain essential structural materials for many demanding engineering applications requiring high strength at elevated temperatures and good performance in environments subjected to high thermal fluctuations such as often encountered in the automotive, rail and aircraft industries. The sand-casting process is one of the most preferred methods of producing complex and intricate shaped components out of metals with good strength at elevated temperatures. Unfortunately, the sand casting process also leads to the direct and indirect production of carbon dioxide. Three-dimensional sand mold printing has been revolutionizing traditional production methods by reducing the unnecessary consumption of metal and chemicals when manufacturing a part through sand casting. This paper explores the opportunities that are emerging in the area of 3D printing of sand molds and the positive impact that these new technologies and practices are having on the environmental impact of current sand-casting processes. The paper demonstrates that 3D printing of sand molds enables new manufacturing strategies reducing the direct CO2 emissions and reducing the amount of metal required by enabling design optimization of both the component and mold/core assembly. Further benefits will be realized through the development of environmentally friendly binder systems. http://hdl.handle.net/10985/17651 3D printing for rapid sand casting—A review UPADHYAY, Meet; SIVARUPAN, Tharmalingam; EL MANSORI, Mohamed There are many 3D printing technologies available, and each technology has its strength and weakness. The 3D printing of sand moulds, by binder jetting technology for rapid casting, plays a vital role in providing a better value for the more than 5000 years old casting industry by producing quality and economic sand moulds. The parts of the mould assembly can be manufactured by precisely controlling the process parameters and the gas producible materials within the printed mould. A functional mould can be manufactured with the required gas permeability, strength, and heat absorption characteristics, and hence the process ensures a high success rate of quality castings with an optimised design for weight reduction. It overcomes many of the limitations in traditional mould design with a very limited number of parts in the mould assembly. A variety of powders, of different particle size or shape, and bonding materials can be used to change the thermal and physical properties of the mould and hence provide possibilities for casting a broad range of alloys. Limited studies have been carried out to understand the relationship between the characteristics of the printed mould, the materials used, and the processing parameters for making the mould. These deficiencies need to be addressed to support the numerical simulation of a designed part, to optimise the success rate and for economic as well as environmental reasons. Commonly used binders in this process, e.g. furan resins, are carcinogenic or hazardous, and hence there is a vital need for developing new or improved bonding materials. Sun, 01 Jan 2017 00:00:00 GMT http://hdl.handle.net/10985/17651 2017-01-01T00:00:00Z UPADHYAY, Meet SIVARUPAN, Tharmalingam EL MANSORI, Mohamed There are many 3D printing technologies available, and each technology has its strength and weakness. The 3D printing of sand moulds, by binder jetting technology for rapid casting, plays a vital role in providing a better value for the more than 5000 years old casting industry by producing quality and economic sand moulds. The parts of the mould assembly can be manufactured by precisely controlling the process parameters and the gas producible materials within the printed mould. A functional mould can be manufactured with the required gas permeability, strength, and heat absorption characteristics, and hence the process ensures a high success rate of quality castings with an optimised design for weight reduction. It overcomes many of the limitations in traditional mould design with a very limited number of parts in the mould assembly. A variety of powders, of different particle size or shape, and bonding materials can be used to change the thermal and physical properties of the mould and hence provide possibilities for casting a broad range of alloys. Limited studies have been carried out to understand the relationship between the characteristics of the printed mould, the materials used, and the processing parameters for making the mould. These deficiencies need to be addressed to support the numerical simulation of a designed part, to optimise the success rate and for economic as well as environmental reasons. Commonly used binders in this process, e.g. furan resins, are carcinogenic or hazardous, and hence there is a vital need for developing new or improved bonding materials.