Optimizing Resin Dosage and Sand Grading to Enhance the Properties of 3D-Printed Furan Sand Molds

Authors

  • Han Zheng School of Materials Science and Engineering, Shenyang Ligong University, Shenyang 110159, Liaoning, China
  • Xinhan Zhu School of Materials Science and Engineering, Shenyang Ligong University, Shenyang 110159, Liaoning, China
  • Guoqiang Zhang Liaoning Lianxin Foundry Sand Investment Group Co., Ltd., Shenyang 110000, Liaoning, China
  • Fengguo Liu School of Materials Science and Engineering, Shenyang Ligong University, Shenyang 110159, Liaoning, China
  • Xianfei Zhang School of Materials Science and Engineering, Shenyang Ligong University, Shenyang 110159, Liaoning, China
  • Changsheng Lou School of Materials Science and Engineering, Shenyang Ligong University, Shenyang 110159, Liaoning, China

DOI:

https://doi.org/10.24425/afe.2026.157987

Keywords

3D printed sand molds, Furan resin content, Sand grading, Tensile strength, Permeability

Abstract

This study investigates the influence of resin content, curing agent ratio, curing time, and sand grading on the strength, gas permeability, and gas evolution behaviours of furan resin sand molds in 3D printing-based sand casting. The focus is on optimizing material usage and aligning with sustainable manufacturing objectives to minimize the waste. A multivariate quadratic polynomial regression model was developed through orthogonal experiments and microstructural characterization. The findings indicate that the addition of furan resin is crucial for determining the tensile strength, gas evolution, and permeability of sand molds. Under the process parameters of 2.0% resin content, 40% curing agent ratio, and 24-hour curing time, the sand mold demonstrated a tensile strength of 2.98 MPa, gas evolution of 10.4 mL/g, and permeability of 119.3 AFS. Further increasing the resin content beyond 2.0% resulted in a plateau in the strength gain, accompanied by a sharp increase in gas evolution. The application of an optimized sand grading ratio of 3 parts coarse (150-212 μm) to 7 parts fine (106-150 μm) led to comprehensive performance improvements: the tensile strength increased to 3.02 MPa, gas evolution was controlled at 11.2 mL/g, packing density approached theoretical optimum values, and surface roughness was significantly reduced to a Sa value of 43.478 μm. This study formulates a multi-objective optimization framework and strengthens the theoretical basis for furan resin sand molding in 3D printing, providing industrially viable solutions to minimize typical defects, such as gas porosity and sand adhesion, in real-world casting operations.

References

[1] Oguntuyi, S. D., Nyembwe, K., Shongwe, M. B., Kabasele, J., & Mojisola, T. (2025). A review of the influence of sand properties on parts manufactured by rapid sand casting through additive manufacturing. International Journal of Advanced Manufacturing Technology. 136(5), 1989-2002. DOI: 10.1007/s00170-024-14979-6. DOI: https://doi.org/10.1007/s00170-024-14979-6

[2] Chhabra, M. & Singh, R. (2011). Rapid casting solutions: A review. Rapid Prototyping Journal. 17(5), 328-350. DOI: 10.1108/13552541111156469. DOI: https://doi.org/10.1108/13552541111156469

[3] Kyriakidis, I. F., Kladovasilakis, N., Pechlivani, E. M., & Tsongas, K. (2024). Mechanical performance of recycled 3D printed sustainable polymer-based composites: A literature review. Journal of Composites Science. 8(6), 215, 1-28. DOI: 10.3390/jcs8060215. DOI: https://doi.org/10.3390/jcs8060215

[4] Deng, C., Kang, J., Shangguan, H., Hu, Y., Huang, T., & Liu, Z. (2018). Effects of hollow structures in sand molds manufactured using 3D printing technology. Journal of Materials Processing Technology. 255, 516-523. DOI: 10.1016/j.jmatprotec.2017.12.031.

[5] Zhao, H., Li, L., Ding, S., Liu, C., & Ai, J. (2018). Effect of porous structure and pore size on mechanical strength of 3D-printed combi scaffolds. Materials Letters. 223, 21-24. DOI: 10.1016/j.matlet.2018.03.205. DOI: https://doi.org/10.1016/j.matlet.2018.03.205

[6] Gunther, D. & Mogele, F. (2016). Additive manufacturing of casting tools using powder binder-jetting technology. New Trends in 3D Printing. 53-86. DOI: 10.5772/62532. DOI: https://doi.org/10.5772/62532

[7] Hawaldar, N. & Zhang, J. (2018). A comparative study of fabrication of sand casting mold using additive manufacturing and conventional process. International Journal of Advanced Manufacturing Technology. 97(1), 1037-1045. DOI: 10.1007/s00170-018-2020-z. DOI: https://doi.org/10.1007/s00170-018-2020-z

[8] Sivarupan, T., Balasubramani, N., Saxena, P., Nagarajan, D., El Mansori, M., Salonitis, K., Jolly, M. & Dargusch, M. S. (2021). A review on the progress and challenges of binder jet 3D printing of sand moulds for advanced casting. Additive Manufacturing. 40, 101889. DOI: 10.1016/j.addma.2021.101889.

[9] Kosuge, K., Sunaga, M., Goda, R., Onodera, H. & Okane, T. (2018). Cure and collapse mechanism of inorganic mold using spherical artificial sand and water glass binder. Materials Transactions. 59(11), 1784-1790. DOI: 10.2320/matertrans.f-m2018838. DOI: https://doi.org/10.2320/matertrans.F-M2018838

[10] Anwar, N., Jalava, K. & Orkas, J. (2023). Experimental study of inorganic foundry sand binders for mold and cast quality. International Journal of Metalcasting. 17(3), 1697-1714. DOI: 10.1007/s40962-022-00897-4. DOI: https://doi.org/10.1007/s40962-022-00897-4

[11] Bobrowski, A. & Grabowska, B. (2012). The impact of temperature on furan resin and binders structure. Metallurgy and Foundry Engineering. 38(1), 73-80. DOI: 10.7494/mafe.2012.38.1.73. DOI: https://doi.org/10.7494/mafe.2012.38.1.73

[12] Kamińska, J., Puzio, S., Angrecki, M. & Łoś, A. (2020). Effect of reclaim addition on the mechanical and technological properties of moulding sands based on pro-ecological furfuryl resin. Archives of Metallurgy and Materials. 65(4), 1425-1429. DOI: 10.24425/amm.2020.133709. DOI: https://doi.org/10.24425/amm.2020.133709

[13] Zheng, J., Hu, X., Tang, B., Qi, T., Pan, Q., Zhu, J., Jia, R., Qui, X., Zhang, Z., Guan, A., Ling, W., Peng, T. & Wang, W. (2024). Promoting sustainability in 3D printed sand casting through adaptive sand mold structures. Sustainable Materials and Technologies. 40, e00881, 1-19. DOI: 10.2139/ssrn.4596642. DOI: https://doi.org/10.1016/j.susmat.2024.e00881

[14] Sivarupan, T., Balasubramani, N., Saxena, P., Nagarajan, D., El Mansori, M., Salonitis, K., Jolly, M. & Dargusch, M. S. (2021). A review on the progress and challenges of binder jet 3D printing of sand moulds for advanced casting. Additive Manufacturing. 40, 101889. DOI: 10.1016/j.addma.2021.101889. DOI: https://doi.org/10.1016/j.addma.2021.101889

[15] Hegab, H., Khanna, N., Monib, N. & Salem, A. (2023). Design for sustainable additive manufacturing: A review. Sustainable Materials and Technologies. 35, e00576, 1-16. DOI: 10.1016/j.susmat.2023.e00576. DOI: https://doi.org/10.1016/j.susmat.2023.e00576

[16] Kang, J., Wang, J., Shangguan, H., Zheng, L., Deng, C., Hu, Y. & Yi, J. (2020). Modeling and simulation of the casting process with skeletal sand mold. Materials. 13(7), 1596. DOI: 10.3390/ma13071596. DOI: https://doi.org/10.3390/ma13071596

[17] Zheng, L. I., Zhongde, S., Feng, L. & Yuelong, R. (2021). Research of The Influence Mechanism of multi gradient printing on sand mold performance. Journal of Physics: Conference Series. 1965(1), 012100. DOI: 10.1088/1742-6596/1965/1/012100. DOI: https://doi.org/10.1088/1742-6596/1965/1/012100

[18] Hopp, V., Masoudi Alavi, A., Hahn, D. & Quirmbach, P. (2021). Structure–property functions of inorganic chemical binders for refractories. Materials. 14(16), 4636, 1-15. DOI: 10.3390/ma14164636. DOI: https://doi.org/10.3390/ma14164636

[19] Wang, F., Cui, X., Yang, Q., Song, H., & Li, D. (2023). Fabrication and posttreatment for inorganic binder jetting sand molds for casting. Additive Manufacturing. 73, 103690, 1-15. DOI: 10.1016/j.addma.2023.103690. DOI: https://doi.org/10.1016/j.addma.2023.103690

[20] Zhang, Z., Jiang, L., Sainoki, A., Peng, X., Li, C., Niu, Q., Wang, X. & Gang, M. (2025). Strengthening effect of particle gradation on the mechanical properties of sand powder 3D printed rock analog. Journal of Materials Research and Technology. 35, 1377-1390. DOI: 10.1016/j.jmrt.2025.01.109. DOI: https://doi.org/10.1016/j.jmrt.2025.01.109

[21] Sivarupan, T., El Mansori, M., Coniglio, N. & Dargusch, M. (2020). Effect of process parameters on flexure strength and gas permeability of 3D printed sand molds. Journal of Manufacturing Processes. 54, 420-437. DOI: 10.1016/j.jmapro.2020.02.043. DOI: https://doi.org/10.1016/j.jmapro.2020.02.043

[22] Xu, J., Kang, J., Hu, Y., Shen, H. & Mao, W. (2024). Study on the mechanical properties of 3D-printed sand mold specimens with complex hollow structures. Materials. 17(5), 996, 1-13. DOI: 10.3390/ma17050996. DOI: https://doi.org/10.3390/ma17050996

[23] Gawronová, M., Lichý, P., Kroupová, I., Obzina, T., Beňo, J., Nguyenová, I., Merta, V., Jezierski, J. & Radkovský, F. (2022). Evaluation of additive manufacturing of sand cores in terms of the resulting surface roughness. Heliyon. 8(10), e10970. https://doi.org/10.1016/j.heliyon.2022.e10751. DOI: https://doi.org/10.1016/j.heliyon.2022.e10751

[24] Mocek, J. (2019). Multiparameter assessment of the gas forming tendency of foundry sands with alkyd resins. Archives of Foundry Engineering. 19(2), 41-48. DOI: 10.24425/afe.2019.127114. DOI: https://doi.org/10.24425/afe.2019.127114

[25] Liu, L., Shan, Z. & Liu, F. (2018). High-quality manufacturing method of complicated castings based on multi-material hybrid moulding process. China Foundry. 15(5), 343-350. DOI: 10.1007/s41230-018-8053-y. DOI: https://doi.org/10.1007/s41230-018-8053-y

[26] Ye, D. & Zhang, J. (1990). Arbitrary packing of non-equal spherical bodies. Geological Sciences. 25(2), 127-136. (in Chinese).

[27] Wang, X., Wu, Q., Huang, Y., Li, N., Wu, X., Chen, X., Wang, J., Jing, T., Huang, T. & Kang, J. (2023). Study on the gas release of 3D-printed furan resin sand core during the casting process. Materials. 16(11), 4152, 1-15. DOI: 10.3390/ma16114152. DOI: https://doi.org/10.3390/ma16114152

[28] Mitra, S., de Castro, A. R., & El Mansori, M. (2019). On the rapid manufacturing process of functional 3D printed sand molds. Journal of Manufacturing Processes. 42, 202-212. DOI: 10.1016/j.jmapro.2019.04.034. DOI: https://doi.org/10.1016/j.jmapro.2019.04.034

[29] Wang, Y., Yu, R. L., Yin, S. K., Tan, R. & Lou, Y. C. (2021). Effect of gel time of 3D sand printing binder system on quality of sand mold/core. China Foundry. 18(6), 581-586. DOI: 10.1007/s41230-021-1085-8. DOI: https://doi.org/10.1007/s41230-021-1085-8

[30] Deng, C., Kang, J., Shangguan, H., Hu, Y., Huang, T. & Liu, Z. (2018). Effects of hollow structures in sand molds manufactured using 3D printing technology. Journal of Materials Processing Technology. 255, 516-523. DOI: 10.1016/j.jmatprotec.2017.12.031. DOI: https://doi.org/10.1016/j.jmatprotec.2017.12.031

[31] Nadimi, S., Mendes, J., López, A., Schröer, L., Manoorkar, S., Ellman, S., Cnudde, V. & Bruno, A. W. (2024). Micro computed tomography images of capillary actions in rough and irregular granular materials. Scientific Data. 11(1), 78, 1-7. DOI: 10.1038/s41597-024-02925-w. DOI: https://doi.org/10.1038/s41597-024-02925-w

[32] Liu, R., Zhao, W., Tian, Y., Zhang, J., Luo, G. & Shen, Q. (2024). Effects of hollow sand mold on the microstructure and mechanical properties of a low-pressure aluminum alloy casting. Journal of Materials Research and Technology. 28, 4488-4497. DOI: 10.1016/j.jmrt.2024.01.035. DOI: https://doi.org/10.1016/j.jmrt.2023.12.270

[33] Haach, V.G., Vasconcelos, G. & Lourenço, P.B. (2011). Influence of aggregates grading and water/cement ratio in workability and hardened properties of mortars. Construction and Building Materials. 25(6), 2980-2987. DOI: 10.1016/j.conbuildmat.2010.11.011. DOI: https://doi.org/10.1016/j.conbuildmat.2010.11.011

[34] El-Husseiny, A. (2020). Improved packing model for functionally graded sand-fines mixtures—Incorporation of fines cohesive packing behavior. Applied Sciences. 10(2), 562, 1-16. DOI: 10.3390/app10020562. DOI: https://doi.org/10.3390/app10020562

Downloads

Published

2026-07-13

How to Cite

Zheng, Han, et al. “Optimizing Resin Dosage and Sand Grading to Enhance the Properties of 3D-Printed Furan Sand Molds”. Archives of Foundry Engineering, vol. 26, no. 2, July 2026, pp. 33-41, doi:10.24425/afe.2026.157987.

Issue

Vol. 26 No. 2 (2026)

Section

Articles

License

Copyright (c) 2026 Archives of Foundry Engineering

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

Similar Articles

<< < 1 2 3 > >> 

You may also start an advanced similarity search for this article.