The unique technology of wax 3D printing is vital in numerous areas, such as manufacturing, dentistry, and jewellery. To shape the final components, 3D printing wax creates moulds instead of the actual product. Many fields are quickly moving towards 3D printing wax models as the first choice. 3D printed jewellery made of wax will be worth $989 million in 2031, up from $489 million in 2021, according to last year’s “3D Printing Jewellery Markets 2023: Market Study and Forecast” research. Learn about the ins and outs of wax 3D printing, as well as its typical uses, in this comprehensive guide.
What is Wax 3D Printing?
Using wax or a material that closely resembles wax, 3D printing may produce moulds that are incredibly accurate and detailed. The lost-wax casting process uses these moulds, which are not the finished result. It is possible to create the final product by melting the wax mould and then filling the resulting cavity with metals or polymers.
The capacity to print intricate wax moulds is widely esteemed for the precision, level of detail, and surface quality it provides in terms of dimensions. Creating these moulds by hand was a time-consuming and laborious procedure, but 3D printing has made it much easier and faster.
How Does Wax 3D Printing Work?
Making a digital model of the finished product in 3D modelling software is the first step in the 3D printing of wax. Making a copy of an item sometimes necessitates scanning it first. Sending the finished digital model to a 3D printer that works with wax or plastics that mimic it is the next step.
Adding support structures while printing is necessary for complex designs with overhangs or intricate shapes. There will be a subsequent removal of these supports and smoothing out of any surface imperfections.
Lost-Wax Casting Process
Placing the mould in an oven or other heat source melts the wax within. When the wax melts, it leaves a hole that is filled with molten metal or some other substance. It is possible to see the finished product after the material has hardened by removing the protective layer. Depending on the use case, the product can undergo revisions as needed.
Common Applications of Wax 3D Printing
Many different types of businesses employ wax 3D printing, particularly those that value accuracy and fine detail.
1. Jewelry Making
2. Dentistry
3. Mechanical Engineering
One use of wax 3D printing in mechanical engineering is the creation of moulds for intricate cast-iron components. Before going into mass production, engineers can use the method to create and test prototypes of the parts.
4. Medical Field
Advantages of Wax 3D Printing
The numerous advantages of wax 3D printing make it an invaluable resource in many different industries. Among the most important benefits are:
Precision and Accuracy
Moulds made with wax 3D printing can be incredibly accurate and intricate. With the right printer, the method can get an accuracy of about 25 micrometres (μm). Exacting dental models or intricate jewellery pieces necessitate such a degree of accuracy.
Cost-Effective for Prototyping
Particularly for making prototypes and low-volume production runs, the approach is economical. Depending on the complexity, wax 3D printing can create models in a matter of hours, but traditional ways of manufacturing wax moulds can take weeks. Faster iteration of designs and early resolution of problems are both aided by this turnaround time.
Sustainability
When compared to more conventional processes, wax 3D printing offers a greener alternative. Reducing material waste, the technique only uses the amount of wax that is necessary. You can either reuse the melted wax or burn it to get rid of any residue.
Design Freedom
Thanks to 3D printing, complicated and detailed designs that were previously impossible to accomplish manually are now within reach. Using wax 3D printing, designers have more freedom to create intricate mechanical components or fine jewellery.
The Wax 3D Printing Process in Detail
The wax 3D printing method is explained in great depth here:
Step 1: Construct the Model
Developing the model with 3D scanning or software comes first. Making the digital file suitable for print comes next.
Step 2: Print the Wax Model
The three-dimensional printer creates the wax model layer by layer. For increasingly complex designs, it is standard procedure to add and then eliminate supports during printing.
Step 3: Attach to Casting Tree
The technique starts after printing to fasten the produced wax model to a casting tree, perhaps housing many models.
Step 4: Creating Mold
To form the mould, soak the casting tree in a mixture of ceramic, plaster or clay. This dries to become the outside of the mold.
Step 5: Melt the wax.
Just heat the mould till it melts to release the wax and expose the intended form of the mould.
Step 6: Cast the Final Material
Casting the final material is the pouring molten metal, resin, or some other substance into a mould. Once the substance has set, one can remove the exterior mould.
Step 7: Post-Processing
Further modifications could be required to reach the needed degree of surface quality or precision for the particular use once processing is finished.
Filaments Used in Wax 3D Printing
1. PolyCast™ Filament
Key features:
- Printing Temperature: 190˚C – 220˚C
- Bed Temperature: 25˚C – 70˚C
- Printing Speed: 40mm/s – 60mm/s
- Fan: ON
- Retraction Distance: 1mm
- Retraction Speed: 20mm/s
Nothing compares in investment casting to the creative 3D printing filament PolyCastTM. The Layer-FreeTM technology of the filament guarantees a high-quality surface polish that will be transferred to the cast product, therefore facilitating easy smoothing with IPA. Ash-FreeTM guarantees clean burnouts with reduced ash residue for precise investment casting. Because it can print at temperatures between 190˚C and 220˚C with a bed temperature ranging from 25˚C to 70˚C, this printer is flexible. The retraction settings may vary depending on whether you use an indirect or direct drive system, therefore providing the control required for best outcomes. PolycastTM is an excellent approach to decrease manufacturing time and costs since it eliminates tooling procedures.
Price: $49.99
2. Machinable Wax (Blue)
Key features:
- Hardness: 53 (Shore “D” Scale)
- Penetration @77 deg. F, 150g (dmm) = 13.0
- Specific Gravity: 0.92
- Specific Density: 0.92949 grams / cubic cm
- Flash Point (COC): 575 degrees F
- Melt Point (Ring & Ball Method): 240 degrees F (116C)
Because of its robustness and amazing detail, machinable wax—a high-performance, multifarious wax ideal for CNC machining and lost-wax casting—is Among the sectors that might profit from its stiff character—which allows exact milling—are prototyping, dental CAD/CAM, and jewelry design. For places with limited air circulation, the wax is non-stick and generates less dust during processing. One of its unique features is its complete recyclability; this helps to lower production costs and material waste. Since this wax comes in blocks and cylinders, it is flexible enough for usage in many different machining configurations. Its 53 Shore D hardness qualifies it for creating intricate models without compromising dimension accuracy.
Price: $7
3. MOLDLAY Filament
Key Features
- Very low warping
- Low viscosity at higher temperatures
- High dimensional stability
- Rigid and dimensionally stable
- Printing also possible without heatplate
- Pressure temperature between 170° and 180°C
Mould manufacturing is suitable for MOLDLAY Filament, a specialist filament used with 3D printers that resembles wax. Because of its unique properties—which allow it to be extruded at low temperatures, between 170 and 180°C—anyone with an FDM printer can use it. This filament is ideal for everyone engaged in mold-making or lost wax casting because of its great dimensional stability and toughness once cooled. MOLDLAY will provide you with exact results free of distortion regardless of the complexity of your design or the purpose of the part you are creating.
Mould-making requires MOLDLAY’s great adaptability and simplicity since its low viscosity at higher temperatures makes work easier. Although a bed temperature of 40°C will yield the best results, a heated bed is not required to print it—a major bonus. For those looking for substitutes for PLA and ABS, this filament lets users explore new creative possibilities without the need for expensive SLS or SLA printers, therefore saving costs.
Price: $64
Having looked at wax 3D printing, it’s also important to have a look at the best 3D printing software that you can use to prepare your files. There are many that are available, but we recommend using SelfCAD. It is an easy-to-use 3D design software that you can use to create both simple and complex 3D models. It also comes with 3D printing tools like the in-built online slicer useful for slicing your files and generating the G-code to send to your 3D printer.
Conclusion
Wax 3D printing is one of the best and flexible techniques for areas that appreciate accuracy and complexity. Affordable, eco-friendly, and sustainable it satisfies the strict criteria needed in disciplines ranging from mechanical engineering to dentistry to jewelry.
Though not the fastest or most direct 3D printing technique, wax 3D printing is obviously better when casting complex components. Whether you’re creating one-of- a- kind jewelry or prototypes for industrial components, Wax 3D printing is a great tool for boosting production accuracy and creativity.
