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Polymaker PolyCast PVB Filament

SKU: PMPM-1014

The Specialty family offers unique filaments from Polymaker to open up new 3D printing applications.

PolyCast is a filament designed for the production of investment models for investment casting applications. The 3D printing process significantly reduces both cost and lead time by eliminating the process of tool manufacture.

Special features:

Combustible
Suitable for the manufacture of moulds
Easy to print

Color (Please select): Natural
Diameter (Please select): 1,75 mm 1,75 mm

2,85 mm 2,85 mm
Weight (Please select): 750 g 750 g

3.000 g 3.000 g

from

€ 54,95

€ 73,27 per 1 kg

incl. 19% VAT ,

Available immediately

This item has variations. Please select the requested variation.

Polymaker PolyCast PVB Filament

from

€ 54,95

€ 73,27 per 1 kg

incl. 19% VAT ,

This item has variations. Please select the requested variation.

Fast shipping

13+ years experience

Secure payment

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Description
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Creating Casting Molds with Polymaker's PolyCast Filament

Polymaker has developed a second material (in addition to Polymaker PolySmooth) that utilizes Layer-Free technology. This material is a specialized casting material that can replace the wax models used in the investment casting process. The use of Layer-Free technology is combined with Polymaker’s Ash-Free technology to create a 3D printing filament that molds very well and burns very cleanly. The material is called PolyCast and was developed specifically for the metal casting industry. The process of manufacturing metal parts from wax models is well-established, and PolyCast integrates seamlessly into this process without disrupting traditional methods. Instead of casting wax models, which are then used to create a ceramic mold, users can 3D print PolyCast models that replace the wax while simultaneously eliminating the need for tools or injection molding. Tooling is often the limiting factor in bringing new products to market, as it is time-consuming and costly. PolyCast enables faster design iteration and is not limited by part counts or large minimum order quantities. This significant time and cost advantage has led to PolyCast being adopted by many foundries around the world. Without deviating from their proven processes, they can test new geometries and streamline production through the use of additive manufacturing and PolyCast.

As mentioned earlier, PolyCast also features Layer-Free technology, which allows 3D-printed parts to be polished to a smooth, glossy finish. This significantly simplifies the casting process, as bubbles can become trapped between layers, leading to defects in the mold that are transferred to the metal parts. A typical investment casting process proceeds as follows. CAD designs are 3D-printed using PolyCast and then polished in the Polymaker Polysher. They are then attached to a wax tree, which can hold multiple parts and consists of sprues and runners that guide the flow of molten metal. The tree is then dipped into a ceramic slurry that coats all surfaces of the tree and the 3D-printed parts. Next, a silica particle is sprayed on, which gives the mold thickness and strength. This process is repeated until a ceramic shell has formed around the 3D-printed parts that is thick enough to withstand the molten metal. The ceramic shell is then fired in a kiln at temperatures of 1200 °C, causing the ceramic to harden and creating a very hard and heat-resistant shell. During this process, the 3D-printed patterns are burned out of the ceramic shells. Ash-Free technology typically leaves an ash residue of 0.003% by weight after firing. This means that the 3D-printed part has completely vaporized due to the high temperatures in the kiln, resulting in a very clean casting surface on the inside of the ceramic mold. Molten metal is then poured into the molds, where it solidifies in the shape of the 3D-printed parts. The metal tree is then separated from the brittle ceramic shell, and the individual parts are cut out of the tree, which can then be recycled. The parts are generally finished using a CNC milling machine to achieve the desired tolerances for precision machinery. In some cases, metal parts can be easily cleaned by hand and are ready for production even without CNC milling. A completely ash-free mold is crucial for the final quality of the metal part and is the key technology used at PolyCast. Layer-Free technology ensures a bubble-free boundary layer on ceramic molds and also seals all surfaces of the 3D-printed part, reducing the time required for final post-processing of metal parts.

Layer-Free technology has given 3D-printed parts the finishing touch, bringing them into the league of traditionally manufactured plastic objects. In addition to all the other advantages of 3D printing, the ability to create a smooth, glossy surface that is waterproof and easy to clean is a major breakthrough for 3D-printed parts that make our modern lives easier every day. By unlocking new geometric shapes, Layer-Free technology has helped open new doors for mold housings, enabling shorter lead times and greater customization of metal parts. This, in turn, will benefit many other industries and have a truly global impact as we develop increasingly efficient machines.

Note: In February 2022, Polymaker began transitioning all filaments to cardboard spools. This transition will take place gradually over an extended period. Both the manufacturer and we as a retailer will, of course, first sell off existing stock before the new spools become available. The filament itself remains unchanged by this transition; it is merely a change in packaging, as well as a new EAN and SKU number.