UoA HERA Prize 2024 – 3D printed sandcasting moulds

This year, we’re proud to recognise student innovation at the University of Auckland’s (UoA) final-year display day with our HERA Prize to Sara Renall and Sebastian Webb, who were recognised for their project, 3D printed sand-casting moulds.

Their project explored integrating binder jetting 3D printing technology into sand-casting workflows—a significant step toward flexible manufacturing in heavy engineering. They identified and optimised materials, printing parameters, and post-processing techniques, producing sample molds and cast parts that offer valuable insights for the industry.

Motivation and challenges

Sara and Sebastian were drawn to the project through their shared interest for metal casting and passion for 3D printing. They saw it as an opportunity to gain hands-on experience and bring innovation to an established profession.

However, the project came with challenges, particularly in managing lead times and limited casting opportunities. The molds required several days to harden after printing, and printing itself often took an entire day. Any defects caused significant delays, making it difficult to refine designs quickly and iterate efficiently.

Supporting research and future plans

Under the guidance of Olaf Diegel, their research highlighted how additive manufacturing can complement traditional casting methods, addressing current and future challenges in heavy engineering. We acknowledged their dedication and contributions, emphasising the importance of their work in advancing the sector.

Having successfully completed their degrees, Sara will soon begin her full-time career in industry as a Mechanical Graduate Engineer, while Sebastian is exploring further academic opportunities. Both are eager to continue applying their knowledge of 3D printing processes for casting operations, recognising its potential to drive future innovation.

Their project not only demonstrates the value of integrating 3D printing into sand-casting processes but also reflects the innovative spirit shaping the next generation of heavy engineering professionals.

Keen to get an innovation project off the ground yourself?

The team at HERA is here to help! Please get in touch with Holger.