Mindanao State University - Iligan Institute of Technology

COLLEGE OF ENGINEERING
Department of Materials and Resources Engineering and Technology
MET169.2 | Adaptive Metallurgy Lab| Engr. Argel Mugot

PROTOTYPE DEVELOPMENT OF CASTING PATTERN WITH

INTEGRATED SYSTEM

Laurence M. Bayhonan, James Rexson E. Cayasa, Angel Ivy V. Gasal, Crepelle R.

Odian

ABSTRACT

This activity focuses on the design and prototype development of a rolling pin casting pattern
with an integrated gating system using AutoCAD. The primary objective is to evaluate the
efficiency of the gating system and optimize the flow of molten metal during casting. A
pattern was developed following essential design principles, including shrinkage allowances,
draft angles, and smooth metal flow. The prototype was fabricated using available materials
and tested for feasibility in a casting process. The results demonstrated a functional design
that minimizes casting defects while maintaining accuracy and efficiency. Challenges such as
pattern surface finish and gating placement adjustments were identified and addressed. The
activity highlights the importance of proper pattern design in ensuring high-quality cast
products and proposes improvements for future versions.

INTRODUCTION

Casting is one of the oldest and most

widely used manufacturing processes,
where molten metal is poured into a mold
to form a solidified shape. It is commonly
employed in industries such as automotive,
aerospace, and construction due to its
Figure 1. Schematic of a traditional
ability to produce complex geometries
gating system layout
with high accuracy

Prototype Development of Casting Pattern with Integrated Gating System | MET169.2

A crucial aspect of successful casting is achieving defect-free castings and
the gating system, which controls the flow cost-effective production.
of molten metal into the mold cavity. The
design and optimization of gating systems
in casting processes are critical for OBJECTIVES OF THE STUDY
ensuring the quality and efficiency of
This laboratory activity aims to:
metal castings. Gating systems control the
1.​ Apply pattern making principles to
flow of molten metal into molds, and their
design a prototype suitable for the
design can significantly impact the
casting process.
occurrence of defects such as cold shuts
2.​ Select appropriate materials for the
and gas entrapment (Campbell, 2015). A
pattern and gating system to ensure
well-designed gating system ensures
optimal casting performance.
smooth metal flow, minimizes turbulence,
3.​ Optimize the gating system design
and reduces common defects like porosity,
to improve metal flow and
shrinkage, and inclusions.
minimize casting defects
Prototype development of a casting pattern
with an integrated gating system plays a SIGNIFICANCE OF THE STUDY
vital role in optimizing the casting process.
The activity to make a prototype
By creating and testing a prototype,
development of a casting pattern with an
manufacturers can evaluate the
integrated gating system is significant in
effectiveness of the gating system, identify
various aspects, particularly for students,
potential defects, and make necessary
the casting process, and the field of
design adjustments before full-scale
manufacturing.
production. This approach improves
casting quality, reduces material waste,
This activity allows students to gain
and enhances efficiency. Additionally,
hands-on experience in pattern-making,
simulation and experimental testing of the
material selection, and gating system
prototype enable better process control and
design, essential for efficient metal
repeatability in manufacturing. Thus,
casting. By applying theoretical
integrating a well-designed gating system
knowledge to a practical setting, students
in the prototype phase is essential for
enhance their problem-solving skills,

Prototype Development of Casting Pattern with Integrated Gating System | MET169.2

creativity, and technical expertise. At the Planning
same time, the activity contributes to the The casting requirements for the rolling
advancement of casting processes by pin were defined, including material
promoting precision, defect reduction, and selection, dimensions, shrinkage
sustainable material use. Furthermore, it allowance, and draft angles to ensure
supports better casting quality, reduces accurate molding.
waste, and encourages sustainable
manufacturing, making it beneficial for Deciding on the Pattern Design
both learning and industrial applications. The pattern design was then decided based
on functionality and casting feasibility,
MATERIALS AND METHODS ensuring that it would leave precise and

The materials used for this activity were seamless imprints on the sand mold.

polymer filament, 3D Printing Machine,

and Laptop for auto CAD. AutoCAD Modeling of the Pattern

Flowsheet AutoCAD was used to create a 3D model

of the rolling pin, incorporating proper
allowances and smooth surface contours to
facilitate high-quality casting.

Gating System Design & Integration

Gating system was designed and integrated
after the pattern was finalized, including
the placement of the sprue, runner, and
riser to optimize metal flow and minimize
defects like turbulence and shrinkage.
Adjustments were made to ensure proper
gating placement and flow efficiency.

Finalizing CAD Model

Figure 3. Pattern Making Process Flow The final CAD model was reviewed, and
necessary modifications were applied
before proceeding to fabrication.

Prototype Development of Casting Pattern with Integrated Gating System | MET169.2

Printing the Pattern (FABLAB)
The 3D printing process will then be
carried out at FABLAB, using polymer
filament materials such as PLA or ABS.
The printed pattern will be carefully
cleaned to remove dust, debris, and
imperfections, ensuring a smooth surface
finish for accurate mold formation. This
Figure 4.2 Finished 3D model
structured approach allowed for a precise,
efficient, and defect-free pattern, ready for
sand mold preparation and casting.
Pattern Pin

Material Plastic
RESULTS AND DISCUSSION Dimension 4 inches

Tools for Shaping 3D Printing

RESULTS

Prototype Design and Development:

Pattern Roller

Material Plastic

Dimension 8 inches

Tools for Shaping 3D Printing

​ The rolling pin casting pattern was

successfully designed using AutoCAD.
Figure 4.1 Design modifications to avoid
The CAD environment allowed for precise
defects in castings
modeling of the rolling pin with smooth
surfaces and rounded edges, minimizing
the need for post-casting machining. This
design consideration is essential in

Prototype Development of Casting Pattern with Integrated Gating System | MET169.2

ensuring a high-quality surface finish and
reducing additional processing time.

The integrated gating system, comprising

the sprue, runner, and riser, was also
Figure 4.3 3D Cad Model of the Rolling
modeled in AutoCAD. Careful attention
Pin with Integrated Gating System
was given to the placement and
dimensions of each component to optimize The gating system’s efficiency was
the flow of molten metal. The gating evaluated based on its ability to ensure
system was designed to minimize smooth and consistent metal flow during
turbulence and promote uniform metal the casting process. The design
flow, reducing the risk of casting defects successfully minimized common defects,
such as porosity and shrinkage. with the sprue and runner effectively
directing molten metal into the mold
Material Selection and Prototype
cavity. The riser was appropriately sized to
Fabrication:
compensate for metal shrinkage during

The prototype was fabricated using solidification, ensuring a defect-free final

polymer filament through 3D printing. product.

This material was chosen for its ease of

DISCUSSION
use, dimensional accuracy, and ability to
produce intricate details required for the Since we are not yet printing the prototype
gating system. The 3D-printed pattern we made in AutoCad, here are several
demonstrated good structural integrity and potential issues that may arise that will
provided a reliable basis for the casting require adjustments to ensure the quality
mold. and functionality of the casting pattern.
One of the primary challenges could be
Evaluation of the Gating System:
related to the surface finish. The
3D-printed pattern may exhibit slight
layering marks from the printing process,
which could transfer onto the mold surface
and affect the quality of the final metal

Prototype Development of Casting Pattern with Integrated Gating System | MET169.2

casting. To address this, sanding and prototype development process will be
post-processing techniques will be applied optimized to achieve the desired standards
to smooth out any rough areas before for casting performance and quality.
proceeding with mold preparation.
CONCLUSION
Another potential issue involves the gating
system design. Initial iterations of the The development of a rolling pin casting
prototype may reveal possible turbulence pattern with an integrated gating system
in the molten metal flow due to the using AutoCAD demonstrated the
suboptimal placement of the sprue. This effectiveness of digital modeling in casting
turbulence could lead to casting defects applications. The CAD-based approach
such as air entrapment and uneven metal allowed for precise pattern design,
distribution. To mitigate this, the gating ensuring proper shrinkage allowances,
system components will be repositioned draft angles, and smooth surface contours
and resized within the CAD model to to enhance casting quality. Additionally,
promote smoother and more efficient the gating system was carefully designed
metal flow before finalizing the print. to optimize metal flow, minimize
turbulence, and reduce defects such as
Lastly, dimensional accuracy might be porosity and shrinkage.
affected due to shrinkage and warping of
the printed pattern during the filament Although the prototype has not yet been
cooling process. This dimensional 3D printed, the analysis highlighted
distortion could compromise the fit and potential surface finish issues, gating
accuracy of the casting pattern. To prevent system adjustments, and dimensional
this, adjustments will be made to the print accuracy concerns.
settings, including slower cooling rates
and modified print speeds, to minimize REFERENCES
shrinkage and maintain the integrity of the
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Handbook: Metal Casting Processes,
Metallurgy, Techniques and Design.
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Prototype Development of Casting Pattern with Integrated Gating System | MET169.2

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Santosh Reddy Sama, Guha P Manogharan

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Prototype Development of Casting Pattern with Integrated Gating System | MET169.2