GLoriA

Generative lost-model process for the CO₂-reduced in-situ production of cast aluminium components

As a result of global challenges such as climate change and the increasing scarcity of resources, established processes urgently need to be made more energy-efficient and lower in CO₂ emissions. Especially for complex, individualized light metal structures, established manufacturing processes such as milling or investment casting often do not make sense from a climatic and economic perspective. The aluminium sand casting technology with the so-called lost foam process offers an efficient alternative, especially for prototypes and small series. In this process, a milled polystyrene model is positioned in a sand mold, decomposed while the molten aluminium is poured in and the model geometry is demolded. However, this process has potential for optimization in terms of cycle times, surface quality and environmental compatibility. The aim of the GLoriA project is therefore to develop a flexible production chain (see Fig.) for the cost-effective and ecological production of customized cast components. To this end, a new type of bio-based plastic granulate and a casting process-adapted printing strategy for sustainable additive model production must first be developed. The integration of bioplastic recyclates and their effects on the process properties in a closed-loop strategy will also be analyzed. Compared to the conventional lost foam process, CO₂ savings of up to 50% are to be achieved with a shorter cycle time and improved surface quality.

Illustration of a process chain. Above: classic lost foam process, below: Gloria process chain. Advantages are listed: ‘Shorter process’, ‘Shorter cycle times’, ‘Less material’, ‘Customised production’. — Comparison of the classic lost foam process (top) with the GLORIA process chain (bottom) – the steps of producing the foam granulate, the milling process and model preparation are to be replaced by additive manufacturing with a sustainable bioplastic.

Period

01.11.2024 – 31.10.2026

Project partners

Funding

Federal Ministry for Economic Affairs and Climate Action (BMWK): Central Innovation Programme for SMEs (ZIM)
Fundingline: 'ZIM FuE-Kooperationsprojekt'
Funding code: KK5047611HD4