Application of 3d resin printing for shell mould casting: A review

Abstract The shell mold casting process is widely used for manufacturing complex-shaped metal parts with high dimensional accuracy. Improving the quality and efficiency of this process has gained increasing attention, especially with the development of 3D printing technologies. This study focuses on three main stages of the process: (1) Pattern fabrication using 3D printing with resin-based additive manufacturing (AM), (2) Shell mold creation, and (3) Metal casting. Among them, the pattern fabrication stage plays a critical role, directly influencing surface quality, geometric accuracy, and burnout performance during mold formation. This paper presents an overview of previous studies related to resin AM technology and evaluates the feasibility of using desktop resin printers for producing casting patterns. Key process parameters such as layer thickness, exposure time, build orientation, and support structures are examined for their impact on pattern quality. In the shell mold stage, factors including slurry material, the number of coating layers, and drying conditions are analyzed regarding shell strength and gas permeability. The final metal casting stage is evaluated based on alloy type, pouring temperature, and cooling rate to ensure surface finish and minimize casting defects. The results indicate that parameters across all three stages are interrelated and collectively affect the final product’s quality. Therefore, an integrated optimization approach is necessary. The study also suggests future research directions, including modeling the relationships between printing and casting parameters, to improve accuracy, reduce costs, and shorten production time.