Rapid Fabrication of Smart Tooling with Embedded Sensors by Casting in Molds Made by Three Dimensional Printing

This paper is to investigate the feasibility of constructing “smart tooling” by embedding thin film sensors, specifically, thin film thermocouples (TFTC) in castings made by molds formed by 3 Dimensional Printing (3DP). This study investigates whether thin film sensors can effectively be cast into larger metal structures and if the sensors survive the casting process. The investigation includes making 3DP molds to produce cast lap joint test bars of aluminum A356 and electroplated nickel to characterize by mechanical testing to find the best process conditions to maximize bond strength between the embedded thin film sensors and the cast material. Lastly molds were made and embedded sensors were placed inside the mold for casting. Some of the embedded sensors survived the casting process. In-situ monitoring of casting process with the embedded sensors was accomplished.