Discover the revolutionary BURNAWAY™ Castable 3D Printing Resin by Monocure3D with our comprehensive guide to investment casting. Developed in collaboration with casting professionals and designed for rapid, clean burnout, BURNAWAY is the future of resin casting materials for MSLA 3D printers. This step-by-step tutorial covers everything from initial setup and calibration to the final steps of casting and post-processing. Whether you’re an experienced caster or new to the field, our detailed instructions ensure perfect results every time. Learn about our FastCast™ technology, get tips for sprueing and investment ratios, and achieve precise, detailed castings with less time and effort. Visit our website for more information and support, and get ready to embark on a successful casting journey with BURNAWAY™ Castable 3D Printing Resin.

Monocure 3D’s BURNAWAY resin is a game-changer for the investment casting industry. This unique material allows for 3D printing at unprecedented speeds while maintaining exceptional accuracy and detail. Proudly developed in Australia with input from casting professionals, BURNAWAY is easy to print, burns fast and clean, and guarantees flawless castings every time. With its rapid printing technology, BURNAWAY outperforms traditional wax-based materials, and its optimal results can be achieved without preheating. Follow our recommended procedures and safety guidelines, and experience the convenience and efficiency of BURNAWAY castable 3D printing resin for yourself.

Introduction

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Overview of BURNAWAY™ Castable 3D Printing Resin

BURNAWAY™ Castable 3D Printing Resin, developed by Monocure3D, is a breakthrough material in the investment casting industry. This unique resin allows for 3D printing at unprecedented speeds while maintaining exceptional accuracy and detail. Designed in collaboration with casting professionals from Clear Mind Jewellery in Canada, BURNAWAY resin is specifically engineered for rapid and clean burnout, making it the ideal choice for MSLA 3D printers. In this comprehensive guide, we will take you through the entire process of investment casting using BURNAWAY resin, from initial setup and calibration to the final steps of casting and post-processing.

Collaboration with Clear Mind Jewellery

The development of BURNAWAY™ Castable 3D Printing Resin was made possible through a close collaboration with Clear Mind Jewellery, a leading jeweler specializing in investment casting. By leveraging their expertise and insights, Monocure3D was able to create a resin that meets the demanding requirements of the jewelry industry. The knowledge and experience of Clear Mind Jewellery have been invaluable in developing a resin that delivers flawless castings every time.

Benefits of BURNAWAY resin

There are several key benefits to using BURNAWAY™ Castable 3D Printing Resin for investment casting:

1. Fast and efficient printing: BURNAWAY resin utilizes rapid print technology, allowing for faster printing compared to traditional wax-based materials. This increases productivity and reduces production time.
2. High accuracy and detail: With BURNAWAY resin, you can achieve precise and intricate castings with exceptional detail.
3. Easy to print: Unlike other castable resins, BURNAWAY resin does not require preheating for optimal results. It can be run at standard room temperature, making it simple and convenient to work with.
4. Clean burnout: BURNAWAY resin is specifically designed for clean burnout, ensuring that the 3D printed models and wax tree burn away completely, leaving a hollow cavity for the molten metal.
5. Versatile compatibility: BURNAWAY resin is compatible with both rapid and conventional burnout schedules, allowing users to choose the best option based on their specific requirements.

By utilizing BURNAWAY™ Castable 3D Printing Resin, you can achieve superior casting results with less time and effort, making it the resin of choice for investment casting applications.

Getting Started

Calibrating the 3D Printer

Before printing with BURNAWAY™ resin, it is essential to calibrate your 3D printer to ensure optimal results. We recommend using a calibration model specifically designed for this purpose, which will help dial in the printer settings with the resin.

Calibration is crucial for achieving the highest level of detail possible in your prints. By following the recommended settings provided by Monocure3D for your particular printer, you can ensure that the printer is correctly configured to work with BURNAWAY resin.

Recommended Settings for BURNAWAY resin

To achieve the best results with BURNAWAY™ resin, it is important to use the recommended settings for your specific 3D printer. Monocure3D provides base settings for popular printers on their website, which serve as a starting point for your own calibration.

These recommended settings have been tested and optimized to achieve excellent print quality and ensure that the resin cures effectively. It is essential to follow these settings and make any necessary adjustments based on your printer’s performance and specific requirements.

Print Safety Precautions

When working with 3D printers and resin materials, it is crucial to prioritize safety. Before printing with BURNAWAY™ resin, be sure to observe the following safety precautions:

1. Personal protective equipment (PPE): Always wear the recommended PPE, such as gloves and safety goggles, as detailed in the safety data sheet provided by Monocure3D. This will help protect you from potential hazards associated with resin handling.
2. Proper ventilation: Ensure that your workspace is adequately ventilated to prevent the accumulation of fumes emitted during the printing process. If necessary, use appropriate ventilation equipment, such as fume extractors or air purifiers.
3. Avoid skin contact: Avoid direct skin contact with the uncured resin. In case of contact, wash the affected area immediately with soap and water.
4. Proper storage: Store the BURNAWAY resin in a cool, dry place away from direct sunlight. Follow the storage instructions provided by Monocure3D to maintain the resin’s integrity and performance.

By following these safety precautions, you can significantly reduce the risks associated with 3D printing and ensure a safe working environment.

Post-Printing Process

Cleaning the Printed Models

After the BURNAWAY™ resin has been successfully printed, it is essential to clean the printed models thoroughly. This cleaning process helps remove any excess resin and prepare the models for post-curing.

To clean the printed models, gently rinse them in a container with recommended cleaning solution, such as Monocure Resin Away. Ensure that the solution covers the entire surface of the models and agitate them gently for a few minutes to remove any uncured resin.

After rinsing, inspect the models for any remaining residue or uncured areas. If necessary, repeat the cleaning process until the models are free of any residue.

Post-Curing the Models

Once the models have been cleaned, it is crucial to post-cure them to ensure the resin’s final hardness and stability. Post-curing involves exposing the models to UV light to complete the curing process and enhance their mechanical properties.

To post-cure the models, place them in a standard UV curing unit and expose them to UV light for a recommended minimum duration of 5 minutes. This duration may vary based on the size and complexity of the models.

After the initial post-curing, rinse the models with water to remove any residue or uncured resin. Inspect the models again to ensure that they are completely cured and free from any defects or imperfections.

Removing Supports

Once the models have been thoroughly cleaned and post-cured, it is time to remove the supports. Carefully inspect the printed models to identify the location of the supports and use side cutters or a sharp blade to remove them.

Exercise caution while removing the supports to avoid damaging the printed models. Take your time and ensure that any leftover support material is removed, leaving the models in their final desired state.

By following these post-printing processes, you can ensure that your printed models are clean, fully cured, and ready for the investment casting stage.

Investment Casting

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Attaching Wax Sprues to the Models

In the investment casting process, wax sprues are essential components that help facilitate the flow of metal and ensure a clean burnout. If your model design does not include integrated sprues, you will need to attach wax sprues to the models before assembling them onto the casting tree.

To attach wax sprues, securely connect your model to a central wax column using a wax adhesive or by melting the wax and creating a bond between the model and the sprue. The angle of the sprue should be approximately 45° to promote a clean burnout and efficient metal flow.

Take care to ensure that the wax sprues are firmly attached to the models, as any loose connection can result in casting defects or metal flow issues during the investment casting process.

Assembling the Components onto the Casting Tree

Once the wax sprues have been attached to the models, it is time to assemble the components onto the casting tree. The casting tree allows for multiple pieces to be cast simultaneously, increasing efficiency and reducing material waste.

To assemble the components onto the casting tree, carefully arrange the models and sprues in a way that maximizes space and ensures proper metal flow. The position and orientation of each component will depend on factors such as design, weight distribution, and casting requirements.

Pay close attention to the overall balance and stability of the casting tree to prevent any issues during the investment casting process. A well-designed and properly assembled casting tree will significantly contribute to the success of your castings.

Determining the Total Weight of the Tree

Before proceeding with the investment casting process, it is crucial to determine the total weight of the casting tree. This step is essential for estimating the amount of metal required for the casting and ensuring that you have sufficient material.

Weigh the entire assembled casting tree using a scale and record the weight. This weight measurement will serve as a guide for calculating the appropriate metal-to-investment ratio and optimizing the casting process.

By accurately determining the total weight of the tree, you can achieve consistency in your castings and avoid any potential issues related to inadequate metal supply.

Choosing the Right Investment Material

The choice of investment material plays a vital role in the investment casting process. Different investment materials offer varying properties such as burnout characteristics, surface finish, and thermal conductivity. Selecting the right investment material will depend on factors such as the type of metal being cast, the size and complexity of the models, and the desired casting results.

For 3D printed models, it is crucial to use investment materials specifically formulated for use with plastics and 3D resins. Monocure3D recommends investment materials like R&R Plasticast or Cerus Optima Prestige for optimal results. These materials have been tested and proven to work effectively with BURNAWAY™ resin.

Always follow the guidelines and safety instructions provided by the manufacturer of the chosen investment material to ensure the best possible casting outcome.

Burnout Procedure

Drying and Hardening the Investment

Before proceeding with the burnout procedure, it is essential to dry and harden the investment material. The drying process helps remove any residual moisture and prepares the investment for the subsequent stages of burnout.

The duration of the drying process will depend on various factors such as the ambient temperature, investment material type, and guidelines provided by the manufacturer. Typically, the drying process can take anywhere between 2 and 6 hours.

Ensure that the investment material is completely dry and hardened before proceeding to the next stage of the burnout procedure. This step is crucial to ensure the structural integrity and performance of the investment during the high-temperature burnout process.

Preheating the Kiln

To prepare for the burnout procedure, preheat the kiln to the recommended temperature. For BURNAWAY™ resin, Monocure3D advises preheating the kiln to 730 degrees Celsius or 1300 degrees Fahrenheit.

Proper preheating of the kiln is essential as it ensures a gradual and consistent increase in temperature, which prevents thermal shock and potential damage to the investment. Carefully monitor the kiln temperature to ensure it reaches the desired temperature before proceeding to the next step.

Recommended Burnout Schedule

The burnout schedule for investment casting is crucial to ensure the successful burnout of the 3D printed models and the wax tree, leaving behind a hollow cavity for the molten metal. Monocure3D recommends the following burnout schedule for BURNAWAY™ resin.

1. Maintain the preheated kiln at 730 degrees Celsius for one hour to fully cure the investment material.
2. Drop the kiln temperature gradually over 1 hour to the casting temperature. The specific casting temperature will vary depending on the metal being used. For example, sterling silver typically requires a casting temperature of 430-480 degrees Celsius or 800-900 degrees Fahrenheit.
3. Hold the kiln at the casting temperature for 1 hour to ensure that the investment is fully stabilized and ready for casting.

It is essential to closely follow the recommended burnout schedule and make any necessary adjustments based on the specific requirements of your casting project. Proper burnout ensures the complete removal of the 3D printed models and wax tree, resulting in high-quality castings.

Rapid Burnout Schedule

Mixing the Investment Material

To achieve a rapid burnout schedule, it is necessary to mix the investment material accurately and in the appropriate ratio. The recommended investment material for BURNAWAY™ resin is R&R Plasticast.

For the rapid 6-hour schedule, mix the investment at a ratio of 36 parts investment to 100 parts water. This thicker mixture facilitates faster and more efficient burnout, ensuring a shorter overall burnout time.

Adhere to the mixing instructions provided by the manufacturer of the investment material and take precautions to eliminate any air bubbles during the mixing process. A well-mixed investment material is essential for achieving consistent and reliable casting results.

Vacuuming the Mixture

After mixing the investment material, it is essential to vacuum the mixture to remove any trapped air. This step is crucial for ensuring a high-quality investment and preventing any issues during the burnout process.

Place the mixed investment material in a vacuum chamber or bowl and run a vacuum to remove any air bubbles from the mixture. Continue vacuuming until the mixture rises and collapses on itself, indicating the elimination of air trapped within the investment.

By vacuuming the investment material, you can achieve a homogenous mixture and eliminate any potential defects caused by air pockets or insufficient density.

Pouring the Investment Material into the Flask

Once the investment material is thoroughly mixed and vacuumed, it is time to pour it into the flask. Carefully fill the flask with the investment material, ensuring that the entire tree structure is covered.

To prevent any air bubbles from being trapped around the models or on textured surfaces, vacuum the flask after pouring the investment material. This step helps minimize the risk of imperfections and promotes a clean burnout.

Allow the investment material to dry and harden according to the guidelines provided by the investment material manufacturer. The drying duration will depend on various factors, including ambient temperature and the specific investment material used.

Drying and Hardening the Investment

The drying and hardening process of the investment material is crucial for ensuring its structural integrity and performance during the burnout procedure. The exact drying duration will depend on the specific investment material and environmental conditions.

Typically, the drying process can take anywhere between 2 and 6 hours. It is essential to allow sufficient time for the investment material to dry completely before proceeding with the burnout process.

Monitor the drying progress and ensure that the investment material is completely hardened before moving forward. A properly dried investment material will contribute to a successful burnout and high-quality castings.

Casting Process

Reaching Casting Temperature

Once the investment material has been dried and hardened, it is time to bring the kiln to the casting temperature. Carefully monitor the kiln temperature to reach the desired casting temperature for the specific metal being used.

Maintain the kiln at the casting temperature for the recommended duration to ensure that the investment is fully stabilized and ready for the casting process. The specific casting temperature and duration will vary depending on the metal and the casting requirements.

Achieving and maintaining the correct casting temperature is crucial for ensuring optimal metal flow and complete filling of the mold cavity. Proper temperature control plays a significant role in the success of the casting process.

Pouring the Molten Metal

Once the kiln has reached the casting temperature and the investment is fully stabilized, it is time to pour the molten metal into the prepared flask. Carefully remove the flask from the kiln, taking necessary safety precautions to prevent burns or accidents.

Pour the molten metal into the flask, ensuring a smooth and consistent flow. Pay attention to the temperature of the metal and ensure that it is within the appropriate range for the specific metal being used.

Fill the flask until the metal covers the entire tree structure and the models. Take care to avoid any splashing or overflow, as it can cause defects or imperfections in the casted metal.

Cooling and Quenching the Flask

After pouring the molten metal, allow the flask to cool for a specified duration to allow the metal to solidify and take shape. The specific cooling duration will depend on factors such as the size and complexity of the casted metal.

Once the cooling period is complete, carefully quench the flask in water to speed up the cooling process and facilitate the removal of investment material. Exercise caution while quenching to avoid splashing or causing any damage to the casted metal.

Quenching helps remove the investment material from the casted metal and prepares it for the post-casting finishing process. Ensure that the casted metal is fully cooled and ready for the next step.

Cleaning the Casted Metal

After the flask has been quenched and the casted metal has sufficiently cooled, it is time to clean and remove any remaining investment material. Use a stiff brush, ultrasonic machine, or a pressure washer to clean off the excess investment material from the casted metal.

Take care to remove all visible investment residue, ensuring that the casted metal is clean and free from any impurities. Thorough cleaning is essential for achieving a smooth and polished finish in the final casted metal.

By following proper cleaning techniques and ensuring the removal of all investment material, you can prepare the casted metal for the post-casting finishing process.

Finishing Touches

Cutting, Sanding, and Polishing the Casted Metal

Once the casted metal has been cleaned and any remaining investment material has been removed, it is time to refine and polish the metal to achieve the desired finish. This step involves cutting, sanding, and polishing the casted metal to create a smooth and polished surface.

Start by removing any excess material or unwanted elements using side cutters or appropriate cutting tools. Pay attention to preserving the overall design and geometry of the casted metal while removing any imperfections.

After cutting, use sandpaper or abrasive tools to smooth the surface of the metal and remove any visible marks or rough areas. Gradually progress to finer grit sandpaper to achieve a progressively smoother finish.

Finish the process by polishing the metal using specialized polishing compounds and tools. This step helps bring out the shine and luster of the metal, enhancing its aesthetic appeal.

Taking the Creations to the Next Level

Once the casted metal has been cut, sanded, and polished, it is time to take the creations to the next level. This can involve various techniques such as stone setting, engraving, or other decorative elements that enhance the overall design and value of the piece.

Consider incorporating additional elements or features that complement the casted metal, creating a unique and personalized piece of jewelry or artwork. This step allows for creativity and customization, showcasing your artistic vision and craftsmanship.

By taking the creations to the next level, you can elevate the final result and create truly exceptional and one-of-a-kind pieces.

Tips and Tricks for a Professional Finish

Achieving a professional finish in investment casting requires attention to detail and the application of specific techniques. Here are some tips and tricks to help you achieve a high-quality and professional finish:

1. Take your time: Investment casting is a meticulous process that requires patience and attention to detail. Take your time at each stage to ensure that every step is completed accurately and thoroughly.
2. Use appropriate tools and equipment: Invest in high-quality tools and equipment specifically designed for investment casting. This will ensure that you have the right tools to achieve the desired finish and produce consistent results.
3. Practice good craftsmanship: Pay attention to the craftsmanship of your casted metal. Ensure that the cuts, sanding, and polishing are done with precision, resulting in clean and well-defined edges and surfaces.
4. Experiment with different techniques: Don’t be afraid to experiment with different techniques and approaches to achieve unique finishes. Explore various finishes, textures, and surface treatments to add depth and character to your casted metal.
5. Seek expert guidance: If you are new to investment casting or want to enhance your skills, seek guidance from experienced professionals or experts in the field. Their insights and tips can help you improve your techniques and achieve better results.

By implementing these tips and tricks, you can achieve a professional finish in your investment castings, making your creations stand out and impress.

Tips and Tricks

Expert Guidance for Successful 3D Printing

To ensure successful 3D printing with BURNAWAY™ Castable 3D Printing Resin, it is always beneficial to seek expert guidance. Engaging with experienced professionals in the field can provide valuable insights and tips to enhance your 3D printing process.

Consider joining online forums, attending workshops or webinars, and participating in industry events to connect with experts and learn from their experiences. By leveraging their knowledge and expertise, you can improve your skills and achieve better results in your 3D printing projects.

Demonstrating Experience and Expertise

When working with BURNAWAY™ Castable 3D Printing Resin and investment casting, demonstrating your experience and expertise can significantly enhance your credibility and trustworthiness. Highlight your past successful projects, share case studies or testimonials, and showcase your portfolio to showcase your skills and capabilities.

Consider obtaining relevant certifications or qualifications that validate your expertise in investment casting. This can further enhance your professional reputation and make you a trusted resource in the field.

Building a strong reputation as an experienced professional will attract clients and opportunities, resulting in a successful career in investment casting.

Ensuring Authoritativeness and Trustworthiness

In the investment casting industry, authoritativeness and trustworthiness are paramount. Clients and customers rely on your expertise and professionalism to deliver high-quality products and services.

To ensure authoritativeness and trustworthiness, stay up-to-date with the latest industry trends, advancements, and best practices. Continuously educate yourself on new techniques, materials, and technologies related to investment casting.

Establish yourself as a thought leader in the industry by sharing your knowledge and insights through articles, blog posts, or social media content. This will position you as an authority in investment casting and elevate your professional standing.

By prioritizing authoritativeness and trustworthiness, you can build a strong reputation and attract clients who value your expertise and commitment to quality.

Conclusion

Summary of BURNAWAY™ Castable 3D Printing Resin

BURNAWAY™ Castable 3D Printing Resin by Monocure3D is a groundbreaking material that revolutionizes the investment casting process. Developed in collaboration with casting professionals from Clear Mind Jewellery, this resin offers rapid, clean burnout for MSLA 3D printers.

By utilizing BURNAWAY resin, you can achieve fast and accurate 3D prints, creating detailed metal parts with ease. The resin’s unique properties, such as its rapid print technology and compatibility with both rapid and conventional burnout schedules, make it the ideal choice for investment casting applications.

With Monocure3D’s step-by-step guide, you can confidently navigate the entire investment casting process, from initial setup to post-processing and finishing touches. Whether you are a seasoned professional or new to investment casting, BURNAWAY resin ensures exceptional results every time.

Encouragement for Happy Casting

As you embark on your investment casting journey with BURNAWAY™ Castable 3D Printing Resin, we want to encourage you to approach each step with enthusiasm and a dedication to excellence. Investment casting is a fascinating and rewarding process that allows you to bring your creative visions to life.

Embrace the knowledge and experiences shared in this comprehensive guide, experiment with different techniques, and never stop learning. With the right tools, materials, and techniques, you can achieve remarkable results and take your investment casting projects to new heights.

Happy casting!

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