AP26198529 – Development of technology for the production of aluminum castings of high complexity using 3D printing of models and castings
Objective of the project – Development and implementation of technology for the production of aluminum castings of complex shapes using 3D printing of models and die casting, which will reduce production costs, reduce manufacturing time and improve product quality for strategically important industries.
Relevance: The relevance of this project is driven by the need to develop high-tech industries with high added value in Kazakhstan and to reduce dependence on imported industrial products. Aluminum cast products are widely used in key sectors of the economy; however, existing production technologies are characterized by high costs, long production cycles, and low environmental efficiency. Traditional casting methods require significant tooling costs and do not provide sufficient flexibility for manufacturing parts with complex geometries. At the same time, additive manufacturing technologies, despite their innovative potential, are limited by the high cost of equipment and production. This creates a need for alternative solutions that combine the advantages of digital manufacturing and conventional casting technologies. The proposed project aims to develop an efficient and economically justified technology that will enhance the competitiveness of domestic production and ensure sustainable industrial development of the country.
Scientific supervisor: Ph.D., Senior Lecturer, Merkibayev Yerik
Expected and achieved results: Within the framework of the project, a technology for producing high-complexity aluminum castings based on the combination of 3D printing of models and investment casting was developed and scientifically justified. An analysis of the thermodynamic properties of polylactide (PLA) was conducted, which made it possible to determine optimal temperature regimes for printing and post-processing. Key parameters of PLA, including glass transition, melting, and degradation temperatures, were identified and their influence on model quality was established. An assessment of available 3D printing technologies was performed, and FDM technology was recognized as the most effective in terms of cost, availability, and technological flexibility. A digital model of a turbocharger impeller with complex geometry was developed, considering hydrodynamic and structural requirements. Experimental work on 3D printing PLA prototypes was carried out, ensuring high accuracy and shape stability. A G-code for printing the models was developed and tested, enabling control over geometry and interlayer adhesion. Studies of refractory coatings for protecting polymer models during casting were conducted, including analysis of various compositions. It was determined that the most effective coating is based on ZrSiO₄ and colloidal SiO₂, providing high thermal resistance and gas permeability. Optimal drying parameters for the refractory coating were developed, including a temperature of 50 ± 5 °C and a duration of 2–4 hours. The high adhesion, uniformity, and stability of the coating during polymer burnout were experimentally confirmed. The obtained results form the basis for implementing the new PRINT2CAST technology, which improves quality, reduces costs, and expands the capabilities of casting production.
List of publications with links to them
- Меркибаев Е.С., Чепуштанова Т.А., Берлибек А.М., Толегенова А.К., Нугумаров Ш.Т. Development of a technology for the production of aluminum castings using 3D printing of models and lost-wax casting // Kompleksnoe ispolzovanie mineralnogo syrya = Complex Use of Mineral Resources. – 2026. – Т. 337, № 2. – С. 108–116. – DOI: https://doi.org/10.31643/2026/6445.22