Split Patterns and Core Boxes for sand casting foundries.

We 3D print split patterns for use directly as loose patterns, for mounting as multiple patterns on plates or as double contraction pattern masters for metal pattern production.
Split Pattern image
Split pattern with core prints, 3D printed in ABS
Core Box image
Core box 3D printed in ABS, to go with the illustrated split pattern
The traditional method of pattern making, using wood to produce patterns and core boxes requires skilled craftsmen. Such people are becoming increasingly scarce and those still working at the craft are usually in high demand with long lead times.
You do not need any experience or knowledge of 3D drawing or printing to use this service. Send us your two dimensional drawing, or simply a dimensioned sketch. From this we can produce a 3D computer model including your required draft angles, machining allowances, contraction and core prints. This 3D computer model is then converted into thin layers by a special programme and used by the 3D printer to produce the required parts.
For small quantity production, the printed patterns can also be used directly as a split or loose pattern. For board mounted multiple patterns, we can either supply the required number of copies, or you can use the original and make your own resin copies; just like wooden patterns are commonly copied. Double contraction can be added at the drawing stage if metal patterns are to be produced from the 3D printed pattern
We can also make the matching split or knock out core box to suit the printed patterns.

Print Size

Maximum size of a single part must fit within a volume of 200mm wide x 200mm deep x 205mm high. Larger items can usually be made by dividing into smaller parts and then joined together after printing.

Materials

Materials available are PLA, Amphora nGen copolyester or ABS. See the materials information page for their respective properties. Patterns and core boxes are usually made in red or black colours respectively, though a wide range of alternative colours are available if required.
3D printed bearing black pattern
Bearing support pattern with core prints 3D printed in ABS
Core box image
Bearing support 1st core box, 3D printed in ABS
Bearing support 2nd core box, 3D printed
Bearing support 2nd core box, 3D printed in ABS