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1
Swain, Luke James. "Modelling ceramic mould deformation in the investment casting process." Thesis, University of Birmingham, 2017. http://etheses.bham.ac.uk//id/eprint/8015/.
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Core and shell deformation during the firing stage of the investment casting process was investigated. Relevant thermo-mechanical and thermal properties were characterised for a commercial core and shell system. A finite-element model was created using the experimentally obtained data. Four major mechanisms were shown to contribute to ceramic mould deformation; general thermal expansion, sintering, phase transformations and creep. The shell system experienced little deformation form phase transformation, the core system exhibited minor deformation from sintering. The sintering behaviour of shell material was observed to be highly dependent on the temperature-time profile of the firing cycle, with lower heating rates resulting in more sintering. The crystallisation of amorphous silica to β-cristobalite in core materials was also seen to follow this trend. A rule of mixtures approach showed that inter-layer interaction in shell materials was minimal. An Avrami-based kinetic modelling approach was applied to pressed silica pellets, showing very good prediction of similar heating rates, but an interaction effect between crystallisation and sintering behaviour needs to be established to predict a wider range of heating cycles. A master sintering curve approach was adapted to incorporate crystallisation to predict the displacement of pellets mimicking core materials. Due to silica crystallisation inhibiting sintering, lower heating rates produced less displacement. In order to validate the finite-element model, an experimental test was developed capturing the deformation of a shell test bar in a three-point bend rig at high temperature using photography. Images were then analysed in ImageJ® to measure the bending of the shell material, this was validated using a transducer attached to a three-point bend knife. Comparison of the finite-element model with the validation test showing good agreement. The creep exponents which were the main proponent of shell bending were optimized to be used in future models.
2
Su, Xiuling. "Computer Aided Optimization of an Investment Bi-Metal Casting Process." University of Cincinnati / OhioLINK, 2001. http://rave.ohiolink.edu/etdc/view?acc_num=ucin998405696.
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Lee, Kevin. "Understanding shell cracking during de-wax process in investment casting." Thesis, University of Birmingham, 2016. http://etheses.bham.ac.uk//id/eprint/6783/.
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In investment casting, the removal of wax from the shell is a critical step which may cause shell failure. It would be advantageous to predict the stress development during de-waxing process with computer simulation. The process was simulated with the consideration of two aspects: (i) The thermo-physical data required to model the shell and wax behaviour in the autoclave environment and (ii) A simulation capable of capturing the interaction between shell, wax and the autoclave environment. Data on mechanical properties, thermal properties, permeability, rheology, thermal expansion and density was gathered for wax and shell as appropriate. Flow-3D was used to simulate the de-wax process such that the shell and wax can be simultaneously modelled. It was shown that the Von misses stress exceeded the expected critical failure stress at certain nodes after steam was introduced to the system. Waxes with higher viscosity were predicted to reach the critical stress sooner. The simulation showed that for the selected drainage orifice sizes that was no or little difference in the time taken to reach the critical stress. Wax compressibility which was considered to represent shell permeability was predicted to have a large effect on shell cracking prediction. In general, the statistics of failure in validation test limited the conclusions that could be drawn. Waxes predicted to show differences in cracking and drainage with increasing orifice size did so in the experiment. The simulated drainage times were greater than determined experimentally by around 380s and this requires further investigation.
4
Charmeux, Jean-Francois. "Capabilities of the Investment Casting process for producing meso/micro metal castings using Rapid Prototyping manufacturing routes." Thesis, Cardiff University, 2007. http://orca.cf.ac.uk/54701/.
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This thesis examines the capabilities of different Rapid Prototyping (RP) manufacturing processes for producing sound metallic parts incorporating features in the micrometre range using the Investment Casting (IC) process. RP has been growing in the past twenty years and is nowadays widely employed in the area of precision investment casting since the technology offers the possibility of manufacturing wax patterns which can be directly implemented into investment casting. Owing to the steady improvements of the technology, some of the recently developed RP building machines offer the possibility of manufacturing small parts incorporating micro-features. In this work, a detailed description of the accuracy and capabilities of the IC process regarding its potential for producing sound meso/micro components is given using two types of conventional RP machines. The results of this analysis are then compared through a benchmarking study with a recently developed RP process suitable for the direct manufacture of ceramic moulds. The different technological chains are compared regarding their overall accuracy, surface finish, the amount of structural defects present in the castings and their relative production costs and lead-time. Finally, the potential of the investment casting process for manufacturing sound micro-castings with high aspect ratio is approached from a structural point of view. Through a metallographic analysis study, the research investigates the size-scale effect of cast micro-components upon their microstructure and the subsequent changes in their mechanical properties.
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ZHOU, XINYU. "COMPUTER SIMULATION AND LOW-COST OPTIMIZATION OF AN INVESTMENT BI-METAL CASTING PROCESS." University of Cincinnati / OhioLINK, 2005. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1123793441.
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Hague, R. J. M. "The use of stereolithography models as thermally expendable patterns in the investment casting process." Thesis, University of Nottingham, 1997. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.339642.
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Raza, Mohsin. "Process development for investment casting of thin-walled components : Manufacturing of light weight components." Licentiate thesis, Mälardalens högskola, Innovation och produktrealisering, 2015. http://urn.kb.se/resolve?urn=urn:nbn:se:mdh:diva-27807.
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Manufacturing processes are getting more and more complex with increasing demands of advanced and light weight engineering components, especially in aerospace industry. The global requirements on lower fuel consumption and emissions are increasing the demands in lowering weight of cast components. Ability to produce components in lower wall thickness will not only help to reduce the cost of production but also help to improve the efficiency of engineering systems resulting in lower fuel consumption and lesser environmental hazardous emissions. In order to produce thin-walled components, understanding of mechanism behind fluidity as it is effected by casting parameters is very important. Similarly, for complex components study of solidification morphology and its effects on castability is important to understand. The aim of this work was to investigate casting of thin-walled test geometries (less than 2mm) in aero-space grades of alloys. The casting trials were performed to investigate the fluidity as a function of casting parameters and filling system in thin-walled sections. Test geometries with different thickness were cast and evaluated in terms of filled area with respect to casting parameters, ı.e. casting temperature and shell preheat temperature. Different feeding systems were investigated to evaluate effects of filling mode on castability. Similarly for complex components where geometries are very organic in shape, solidification morphology effects the quality of castings. Process parameters, that effect the solidification morphology were identified and evaluated. In order to develop a relation between defect formation and process parameters, solidification behaviour was investigated using simulations and casting trials. Similarly the effect of factors that influence grain structure and flow related defects were studied. It was observed that fluidity is affected by the mode of geometry filling in investment casting process. The filling mode also have different effect on defect formation. A top-gated configuration is strongly affected by casting parameters where as a bottom-gated configuration is more stable and thus fluidity is not significantly affected by variation in casting parameters. Less porosity and flow-related defects were observed in the bottom-gated system as compared to top-gated system. In the study about casting defects as affected by process parameters, it was observed that shell thickness is important to avoid interdendritic shrinkage. It was observed that the increased shell thickness induces a steeper thermal gradient which is essential in order to minimize the width of the mushy zone. It was also observed that a slower cooling rate along with a steeper thermal gradient at the metal-mould interface not only helps to avoid shrinkage porosity but also increases fill-ability in thinner sections. The work presented here is focused on the optimization of process parameters, in order, for instance, to improve castability and reduce the casting defects in investment casting process. The work, however, does not focus on externally influencing the casting conditions or modifying the casting/manufacturing process. The future work towards PhD will be focused on externally improving the casting conditions and investigating other possible route of manufacturing for thin, complex components.
8
Lim, Chu-Sing. "The production and evaluation of fibre preform-infiltrated metal matrix composite castings produced by a developed pressure-assisted investment casting process." Thesis, Loughborough University, 1995. https://dspace.lboro.ac.uk/2134/28175.
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The squeeze casting process is well known for its ability to produce castings with good integrity due to the high direct pressure application on the liquid metal during solidification. This concept has been used to squeeze infiltrate fibre preforms with liquid metal for metal-matrix composite (MMC) production. Squeeze casting employs fast cycle times to produce high integrity castings. The squeeze casting process is, however, limited in terms of shape complexity and flexibility (e.g. thin sections). One-offs or small production runs become very expensive to produce because of the complex nature and high cost of the die steel tooling.
9
Čagánek, Radim. "Možnosti uplatnění numerických simulací v technologii vytavitelného modelu." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2018. http://www.nusl.cz/ntk/nusl-382112.
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The diploma thesis deals with the possibilities of using numerical simulation in investment casting technology. The first chapter of practical part deals with the use of simulations in the design of gating system for the shape-complex casting. At the same time, the practical part verified the accuracy of the simulation by test castings on which the X- ray inspection was performed. The results showed that the occurrence of internal defects predicted by simulation corresponded to the locations in the test casts. Next part of the thesis describes improvement of the use of liquid metal (so called “yield”) by numerical simulations. Two specific castings were chosen to perform simulation of current and newly designed variant of the gating system.
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Mazůrek, Tomáš. "Optimalizace skořepinové formy při výrobě odlitků ze slitin Al metodou vytavitelného modelu." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2012. http://www.nusl.cz/ntk/nusl-230072.
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This diploma thesis deals with the possibilities of optimization of ceramic shell molds in the method of investment casting. In the first part is mentioned a complete technological process of the method with focusing on production and quality control of the ceramic shell and components, from which it is produced. The experimental part is divided into two parts, in the first are results of laboratory tests, which were tested both the current ceramic shell and shells which have been considered as a possible replacement. In the second section were verified conclusions of the experimental findings and recommendations of the laboratory results in pilot plant conditions.
11
Mikulka, Vít. "Optimalizace technologie výroby Al odlitku litého metodou vytavitelného modelu." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2010. http://www.nusl.cz/ntk/nusl-228936.
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This diploma theses deals with possibilities of using numerical simulation for optimizing production of highly demanding thin-section casting produced by investment casting process. The casting made of aluminium alloy in which the manufacturing process was very problematic (occurrence of macro and micro shrinkages) has been chosen. By numerical simulation the existing technology has been analysed and based on this the possible reasons for defects found. This was later confirmed also by metallographic examinations. Following to this several options for a new technology were proposed and again by simulation checked their suitability. By comparing all above mentioned options two versions have been chosen in the end which was later tested in production with satisfactory results.
12
Kosour, Vojtěch. "Využití numerické simulace k optimalizaci výroby voskových modelů." Doctoral thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2013. http://www.nusl.cz/ntk/nusl-234157.
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Production of wax pattern model by injection machine is a one of the key phases of Investment casting process. The thesis deals with the development of numerical simulation wax blend injection in to metal die. The possibilities of selection simulation software – ProCast and Cadmould are described in the relation to numerical predictions of wax injection. Creating of material database of selected wax blends is described. The prototype simulations of die filling are made. The special testing die are designed a used for created simulations. The measurements of initial conditions are mentioned.
13
Kolesár, Roman. "Optimalizace technologií vosků a skořepin ve firmě Fimes." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2014. http://www.nusl.cz/ntk/nusl-231531.
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The thesis continue thematically in the previous development of the wax mixtures for the company Fimes. The general description of the investment casting process from the production of the die to casting of the wax pattern is handled in the first part. It is followed by the summary of the previously carried out experiments on cracking the shells. The experimental part describes the individual operations from the production of tested wax patterns to casting in the Boilercláv. The newly developed wax mixture is compared to the wax mixture used by the company Fimes. The experiments focus on the possibility of cracking the shells during the casting process and the dimensional stability of wax mixtures.
14
Bochníček, Štěpán. "Validace numerické simulace průběhu plnění matečné formy voskem a její následná optimalizace." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2013. http://www.nusl.cz/ntk/nusl-230975.
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The main topic of the diploma thesis is simulation of the process when wax is filling the cavity of the "mother" metal die.This knowledge is the neccessary presumption for correct design of the gating system and setting correct injection parameters (temperature, pressure, wax flow) when making wax patterns.
15
Šmatelka, Jakub. "Optimalizace technologie voskových modelů ve firmě Alucast." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2014. http://www.nusl.cz/ntk/nusl-231529.
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This diploma thesis deals with the problem of wax patterns manufacturing in investment casting technology (lost wax process). This technology is very sensitive to the exact execution in each phase of the whole process, from concept design up to the final casting expedition. During most operations, dimensional changes occur, which is affecting the accuracy of the final casting. No matter how big these changes are, but especially if they occur with the least variance. One of the first phases in this technology is making wax patterns. There are several ways of making the wax patterns and this thesis is describing two different methods used in the Alucast foundry. One is based on using “soft waxes” enabling using low pressure machines, the other one on the “hard waxes” where the injection machine with higher presses is being used (SOM). These two above mentioned technologies are compared in this work.
16
Žižka, Jiří. "Optimalizace vtokové soustavy s ohledem na využití tekutého kovu při výrobě Al odlitků technologií vytavitelného modelu." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2020. http://www.nusl.cz/ntk/nusl-416634.
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This diploma thesis deals with the optimization of gating systems of shape-complex aluminum castings produced by investment casting process. Two castings whose massive gating systems make problem with the use of liquid metal (so called yield) were chosen for optimization. Each casting is described in its own chapter. The individual subchapters deal with description of the original and newly designed gating system. Simulation, test castings, X-ray inspection and metallographic examination were performed for each variant. At the end of each chapter there is an evaluation of the results of the optimization of gating system.
17
Odložil, Jan. "Tuhnutí odlitků ve skořepinových formách při odlévání ve vakuu." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2009. http://www.nusl.cz/ntk/nusl-228718.
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Heat transfer during metal pouring and its solidification in the vacuum furnace have been investigated by experiments using model set of castings of different diameters and insulations. The pouring metal was Inconel 713LC alloy based on nickel. The found data have been used for optimization of the numerical simulation of the thermal regime during the both pouring and solidification phases of the process in vacuum. Numerical simulation of the alloy structure in individual castings has been made by the CAFE module of the ProCast software and obtained results compared with the real structure. The optimized boundary conditions can be used for simulation of real castings.
18
Úředníček, Lukáš. "Rozměrová stabilita odlitků ze slitin Al zhotovených metodou vytavitelného modelu." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2008. http://www.nusl.cz/ntk/nusl-228150.
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The aim of this paper is to compare a bottom filling of a ceramic form made by lost wax process and a top filling conventional method. A computer simulation of filling and casting solidification will contribute to this comparison. The comparison includes evaluation of readings DAS and characteristic readings of porosity with chosen varieties of casting. The results show that the readings DAS did not change much but characteristic readings of porosity were much better at bottom filling. The computer simulation also showed a certain contribution in the field of model smelting technology.
19
Kosour, Vojtěch. "Technologie rychlého prototypování za použití metody FDM a současně technologie vytavitelného modelu." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2008. http://www.nusl.cz/ntk/nusl-228152.
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An overview of the development of the Investment Casting market and Rapid Prototyping equipment is given in the introductory part of this diploma thesis. Basic methods of rapid prototyping and the FDM method are futher described in detail. The FDM method is consequently used in the practical part of this work for the preparation of the silicon mould. The largest part deals with the issue of the simulation of pouring process of wax into the silicon mould. A characteristics of the casting wax is made; the parametres, which are inserted into the simulation software ProCAST and the possibilities of their measurement are described. The process of the simulation of the mould filling and its validation with the real filling process are described in detail.
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An-ChunCheng and 鄭安均. "Process and properties of investment material for titanium casting(Ⅱ)." Thesis, 2019. http://ndltd.ncl.edu.tw/handle/674fjm.
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Ssu-WeiLee and 李思葦. "Process and properties of investment material for titanium casting (I)." Thesis, 2019. http://ndltd.ncl.edu.tw/handle/3bud56.
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Cruz, Ana Beatriz Campos. "Simulation and Intelligent Visualization Tool for an Investment Casting Manufacturing Process." Master's thesis, 2019. https://hdl.handle.net/10216/122086.
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Ji, Meng-Hong, and 紀孟宏. "Study on the Thinning and Rapid Drying Ceramic Shell Mold for Investment Casting Process." Thesis, 2011. http://ndltd.ncl.edu.tw/handle/87984363282569210242.
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碩士國立高雄應用科技大學
模具工程系
99
The effects of different water based colloidal silica on the properties of primary and backup slurries and ceramic shell mold have been studied. In addition, fused silica can instead of zircon within primary slurry and stucco due to a low density, low thermal expansion coefficient, low specific heat and other characteristics, and prices of the zircon flours and zircon stucco soar. Therefore, the effects on the slurry and ceramic shell mold properties after fused silica instead of zircon have also been studied. There were three variable combinations within the experiment: (1) Type 1, water based colloidal silica A + zircon flours + zircon stucco, (2) Type 2, water based colloidal silica B + zircon flours + zircon stucco and (3) Type 3, water based colloidal silica B + fused silica flours + fused silica stucco, and mullite flours and stucco were uniformly used as backup refractories. About the effects on slurry properties, the viscosity, rheology, pH, sedimentation rate and water-loss rate were investigated. About the effects on ceramic shell mold properties, the four and a half layers ceramic shell mold was principally investigated on the weight, thickness, drying time, MOR (green strength, hot strength and fired strength), permeability, surface roughness, humidity, and sintering duration. Finally, the practical metal pouring experiment was conducted. The results showed: 1. On the slurry properties, Type 2 and 3 have a slowed rising tendency compared with Type 3. And there is no obvious variation on the slope of pH value, but the slurry slows to gel at high pH. Type 3 can decrease the sedimentation rate and it has a larger amount of water-loss weight. 2. On the ceramic shell mold properties, Type 2 and 3 have a light, thin and drying-time-shorted ceramic shell mold compared with Type 1. On the other hand, Type 2 and 3 also have a higher green strength, lower hot and fired strengths, and a higher hot permeability. MOR has no obvious variation, but permeability increase with sintering duration. And drying time is shorted with the humidity decreased. 3. During the 316L stainless steel casting process, the Type 2 ceramic shell mold can withstand the impact of high temperature liquid metal.
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Tseng, Chen Xian, and 曾丞賢. "Study on the Restrictive Shrinkage of the Wax Injection Mold Cavity for Investment Casting Process." Thesis, 2008. http://ndltd.ncl.edu.tw/handle/98918067761326046502.
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碩士國立高雄應用科技大學
模具工程系碩士班
96
The restrictive shrinkage of the pattern wax by the mold cavity of the wax injection mold has been studied. The basic ideas of designing wax injection mold, the pattern wax, the shrinkage characteristics of ceramic shell mold and casting alloys have been investigated, and then, the shrinkage factors were adjusted to calculate practically the mold cavity dimension. The shrink allowances of pattern waxes and casting alloys were obtained by the test of standard test blocks during the experiments. The experiment was divided in three parts: (1) In order to obtain the shrinkage allowances of the pattern waxes and casting alloys of the investment casting process, the standard test blocks of wax injection mold have been made. (2) The whole shrinkage idea has been applied to the design of wax injection mold; therefore, the factors of dimensional errors were investigated, and the errors were then converted into restrictive shrinkage factors. (3) The restrictive shrinkage idea was employed to the design of wax injection mold, and according to the obtained restrictive shrinkage factors, the dimensions of mold cavity were designed. The results showed, with the proper stripping time, the entire restrictive states of wax pattern can be preserved. Since the restrictive shrinkage type are classified as: (1) complete restrictive shrinkage, (2) partial restrictive shrinkage, and (3) unrestrictive shrinkage; therefore, for the dimensional accuracy, the idea of restrictive shrinkage type shall be considered when designing the wax pattern mold.
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Hsieh, Jay-Ting, and 謝杰廷. "Fabrication of the Primary Coat of Ceramic Shell Mold for Investment Casting by Electrophoretic Deposition Process." Thesis, 2008. http://ndltd.ncl.edu.tw/handle/08587239410160457622.
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碩士國立高雄應用科技大學
模具工程系碩士班
96
Electrophoretic deposition (EPD) is a process that the charged particles in the colloidal suspension move under the DC field between the two electrodes and coagulate on the opposite electric electrode. The benefits of EPD process are simple facilities, low cost, high deposition rate, and good surface finish. Nowadays, EPD is used widely for the fabrication of ceramic film. In this study, EPD process was used to fabricate ZrO2 primary coat on the conductive plastic, then the primary coat was set for drying after EPD process. The conventional shell building process, ie. dipping and stuccoing were practiced and repeated for several times, till the ceramic shell mold were obtained. The effects of applied voltage, deposition time, dispersant, and polymer on the deposition behavior and suspension were studied. The scanning electron microscope (SEM) was applied to investigate the surface morphology of ZrO2 coating. Both the surface roughness and strength (hot strength, fired strength) of the ceramic shell molds made by EPD process and conventional shell building process were measured and compared by surface roughness tester and MOR tester. The wettability of metal/ceramic shell mold was also analyzed. The results showed that the ZrO2 deposit weight increased with increasing applied voltage. However, the rate of deposition reduced gradually with deposition time. The stability of ceramic suspension could be enhanced by the addition of dispersant and polymer. The ceramic shell mold that fabricated by EPD process showed lower surface roughness and poorer wettability than that of conventional shell building process.
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Cho, Wang-tzu, and 卓琬姿. "Improving the Process Quality of Investment Casting Industry via Six Sigma－A Case Study of B Company." Thesis, 2015. http://ndltd.ncl.edu.tw/handle/666m6z.
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碩士國立雲林科技大學
工業工程與管理系
103
Chinese's manufacturing sector, the most important competition in the market, subject to the same competition, in order to break through price competition, improve product quality and highest priority, therefore, the importance of the quality of attention. Business managers can no longer be past the old norms to judge the quality problem, you should have to face up to the current quality problems, introducing appropriate improvement methods. With the advancement of technology faces major companies, the relative quality of the process followed to enhance, reduce product defect rate has become valued by many businesses. There are good and stable quality control process, product defect rate will therefore reduce, you can really meet customer demand and reduce the company's production costs. In order to get the best quality, enterprises should select the most appropriate quality management system tools to assist businesses stable quality, streamline processes, improve efficiency and reduce the cost of the optimal strategy. And promote Six Sigma, it is to obtain one of the best quality management system tools. By pushing Six Sigma, to achieve enterprise restructuring physique, improve profitability, enhance the quality of the best state. In this study, the case of traditional lost-wax casting industry company B as the main object of study, and to collect the relevant literature, the application of Six Sigma improvement techniques to improve the quality of our products problem cases of sand hole defect rate, in order to improve customer satisfaction, reduce product defect rate and save production costs. The results showed that the use of Six Sigma quality improvement techniques and with the SOP and experimental design, which can effectively reduce product defect rate, 21.38% rate of improvement before adverse reduced to 5.4%, reduced scrap and rework costs by the monthly average of 1.07 million to 430 000, Sigma index increased from 2.3 to 3.1; case if the company continued to apply six Sigma DMAIC approach to improve the overall quality of the process, will enhance the company's competitiveness and cost savings. Keywords: Six Sigma, Investment Casting, defection rate, DOE
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Tzou, Guey-Jiuh, and 鄒貴鉅. "The Study on Propeller Manufacturing by Combining the RP/RT Technique with Injection Mold and Investment Casting Process." Thesis, 2004. http://ndltd.ncl.edu.tw/handle/79353808782379466491.
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碩士龍華科技大學
機械系碩士班
92
In order to response the market increasing need, and to improve the traditional manufacturing process technique, and to satisfy many kinds of industry requirement, the application of rapid prototyping technique has grown up rapidly in the world. In this research, a new rapid process has been investigated to combine the RP/RT technique with injection molding and Investment casting process to manufacture a propeller. First, the 3D CAD program, Pro/Engineer, is used to create a propeller 3D CAD model, and find out a parting line from the propeller blade, and also extend the parting line to the model boundary to generate a mold parting surface. Therefore, the 3D propeller solid model can be constructed, and the RP reverse core model can also be constructed by cutting out the block from the propeller model. By using an interface program to transfer the CAD model into STL format and download it into the Zcorp 402 3DP rapid prototyping machine, and use gypsum type of powder (type ZP 100) to produce the reverse core mold of propeller. Then, fill the reverse mold with Pb-Sn alloy and metallic resin material to get Pb-Sn injection mold and metallic resin material injection mold separately. Another process is also used to dip the reverse mold into ZrO2 slurry for coating, and after it is solidified, fill it with aluminum alloy to get an aluminum alloy injection mold. In order to ensure the size accuracy and surface luminosity for the rapid tooling, a CAD/CAM program is also used to convert the 3D propeller CAD model into the NC manufacturing program, and apply it with a CNC machine center to finish the surface. After surfacing the Pb-Sn injection mold and metallic resin material injection mold, the wax propeller prototypes can be injected from an injection machine, and the propeller metal prototypes can be generated rapidly and accurately by using the Investment Casting process to the wax prototypes. The MoldFlow analysis program is also used to find out the optimum molding parameters of the injection process with the aluminum alloy mold, and the precise plastic propellers can be injected from an injection machine rapidly. The advantage of this process is that by combining Zcorp 402 3DP rapid prototyping system with CNC machining center, we can produce Pb-Sn alloy injection mold, metal resin injection mold, and aluminum alloy injection mold easily, then the accurate propeller metal prototypes and plastic prototypes can be got rapidly. This process provides the product develop engineers a quick way to get product for product function test and design modification. In this research, it demonstrates that this process is practical to save product developing time and expenses, and also increase market competition.