Marjom, Zolkarnain and Ahmad Moktar, Ahmad Syazani and Mohamad Kamal, Mohamad Ridzuan (2025) Optimization of 3D printed patterns parameters and two stage burnout process for defect reduction in propeller blades investment casting shell mold. International Journal of Research and Innovation in Social Science, IX (XII). pp. 633-641. ISSN 2454-6186
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Abstract
This study investigates the optimization of 3D-printed investment casting patterns and two-stage burnout parameters to minimize defects in propeller blade manufacturing. A full factorial design of experiments (2⁴) was implemented to analyze the effects of four fused deposition modeling (FDM) parameters—shell thickness, infill density, layer height, and internal pattern structure—on burnout performance. Thirty-two PLA patterns were fabricated and evaluated through a two-stage burnout process: Stage 1 (200–350 °C) assessed air permeability, while Stage 2 (up to 650 °C) examined surface integrity using dye penetrant testing and visual crack inspection. Statistical analysis using GLM ANOVA revealed that air permeability exhibited no significant main effects but was influenced by higher-order interactions, notably Infill× Shell× Pattern (F = 5.067, p = 0.03879) and Layer× Shell× Pattern (F = 6.975, p = 0.01779). Dye penetrant indications were dominated by shell thickness (F = 2135.9, p ≈ 1.84e⁻18), with layer height and multiple interactions also significant. Visual cracking was strongly associated with shell thickness (Fisher exact p = 0.00245), with 1 mm shells reducing defects compared to 2 mm. The findings underscore that shell thickness is the primary factor for Stage 2 defect mitigation, while Stage 1 optimization requires joint tuning of shell, infill, and pattern parameters. The proposed two-stage burnout workflow enables early identification of critical factor combinations, offering a robust approach for improving dimensional integrity and surface quality in additively manufactured investment casting applications.
| Item Type: | Article |
|---|---|
| Uncontrolled Keywords: | Additive manufacturing, Investment casting, Two‑stage burnout, DOE, ANOVA, Air permeability, Dye penetrant, Cracking |
| Divisions: | Faculty Of Industrial And Manufacturing Technology And Engineering |
| Depositing User: | Sabariah Ismail |
| Date Deposited: | 23 Feb 2026 01:23 |
| Last Modified: | 23 Feb 2026 01:23 |
| URI: | http://eprints.utem.edu.my/id/eprint/29505 |
| Statistic Details: | View Download Statistic |
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