College - Author 1

College of Engineering

Department - Author 1

Mechanical Engineering Department

Degree Name - Author 1

BS in Mechanical Engineering

College - Author 2

College of Engineering

Department - Author 2

Mechanical Engineering Department

Degree - Author 2

BS in Mechanical Engineering



Primary Advisor

John Fabijanic, College of Engineering, Mechanical Engineering Department


Dr. Xuan Wang, an Industrial & Manufacturing Engineering (IME) professor at California Polytechnic State University, San Luis Obispo, has sponsored the resin-based 3D printing investment cast senior project. The objective of the project was to thoroughly research the process and document the findings of using a resin-based 3D printed part as the pattern for investment casting. While this manufacturing process is not necessarily a new idea, the lack of technical research and documentation limits its ability to be reproducible. The research portion of the senior project included analyzing the limitations to the printing/casting manufacturing process. Measurements of part thicknesses, hole radii, depths, protrusion heights, and fillets were quantitatively studied, and surface finish, pattern clarity, and overall success were determined qualitatively. Three test coupons were manufactured and measured, both for limitations and statistical analysis on growth rates. The features measured for a statistical analysis of the growth included side lengths and diameters for intrusions and extrusions. Once the manufacturing process was sufficiently analyzed, the findings were used to produce a curriculum package for the IME 470 foundry course at Cal Poly. This included a detailed lab manual and video tutorial to promote student learning, as well as a library of CAD models for the students to manufacture. This library contains several models, including dice, rings, and die- casting molds for actions figures. To validate the completeness of the curriculum materials, a group of five students were walked through the process, and useful feedback was gathered to improve the course contents. In total, the project was a success for determining the technology’s limitations and providing educational content to the IME 470 course.

Included in

Manufacturing Commons