Water-Soluble Sacrificial Molds: A New Frontier in Aluminum Investment Casting
Researchers have developed an innovative indirect additive manufacturing method for aluminum investment casting, using water-soluble polyvinyl alcohol (PVA) sacrificial molds to overcome traditional limitations. The technique, detailed in a 2025 study, uses FDM 3D printing to create PVA molds, which are then injected with wax. The PVA is dissolved, leaving precise wax patterns ready for casting.
This approach eliminates the need for support removal and reduces pyrolysis residues during dewaxing—common issues with direct 3D-printed sacrificial structures. It enables the production of complex metallic lattice structures, valued for their low density, high energy absorption, and damping properties. These lattices are ideal for heat exchangers, energy absorption systems, and medical scaffolds.
Experimental results confirm the method’s feasibility for rapid prototyping and low-volume production. By combining additive manufacturing flexibility with investment casting precision, the technology opens new avenues for aluminum components in high-performance applications. As demand for multifunctional materials grows, water-soluble sacrificial molds are poised to become a key enabler of innovation.
Room 805, Huaxu Building, NO.95 Renmin South Road, Taicang City, Jiangsu Province, Suzhou, Jiangsu, China