This project was part of a vintage racing motorcycle replica. The original parts were 3D scanned and reverse engineered to create virtual CAD models. Then they were mirrored to create matching left and right offset heads, that were then sent to an HP Multi Jet Fusion 3D Printer. This machine prints using a Nylon powder, and produces near isotropic (homogenous) models, that are very tough and durable, at 5 times the speed of machines that produce parts that aren’t even comparable to these parts.

Sand Casting Match Plate

These models, and the necessary gates, runners, pouring basin, and riser, were attached to a 3/8″ thick aluminum waterjet cut Match Plate, which makes production Sand Casting a simple process. Due to the slippery nature of this Nylon material, these patterns are easily removed from the Sand Casting molds.

 

Engine Head Patterns

This is the virtual CAD model used to print these patterns.

 

Reverse side of the Match Plate

The reverse side of the Match Plate, with the riser in the center and the bottom concavity of the heads that will interface with the cores to create the valve seats, during the casting process.

 

Corebox’s

The intake and exhaust cavities, each required a corebox to produce the cores, to create the internal cavities.

 

CAD models of the corebox’s and the gate’s, runner’s, and pouring basin assembly, along with the riser.