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Filling and solidification of molten metals are very complex and difficult to simulate correctly by conservative methods. For a large industrial application, it needs an alternate approach that is fast, reliable and user-friendly. In current casting industries, product development paradigm is shifting from traditional trial-and-error in the workshop to computer-aided casting design and simulation package by a computer(s). Computer-aided casting simulation plays an important role in the paradigm of new product development by way of modeling entire casting processes and reveals a dynamic behavior of casting scheme in working conditions. This study, highlighting is given on using casting simulation software which helps foundry industries to design and analysis the size and shape of the riser. Intended for simulation simplification in this study, grain size of mold green sand, casting material quality, casting process parameters are deliberated identical for all design schemes. Only the shape and dimensional variances of sprue/risers are taken into considerations for defects analysis. It is found that defects such as micro and shrinkage porosities, and improper solidification, are directly related to gating and risers system. Casting simulation software is used for mold filling and solidification analysis and it is observed that the proposed gating and risers system design will improve casting results with small defects. From this study, the conclusion can be stated that taper sprue design, also acts as a riser, with an additional four small risers that will produce a small fraction of porosity inside of the casting part. Validation of simulation, in the future, will be proved through experimental trials in the foundry shop.

Teknologi 3D Printer DLP (Digital Light Process) adalah mesin pencetak 3 dimensi yang berbahan resin dengan system penyinaran menggunakan proyektor cahaya dengan proses pencetakan lapis demi lapis. Pada penelitian ini penulis akan membuat objek yaitu salah satu komponen permesinan yaitu casing gearbox. Dalam penelitian ini penulis akan menganalisa pengaruh parameter proses (exposre time, off time, dan interkasi keduanya) terhadap dimensi hasil cetak dan mendapatkan parameter paling optimal guna diaplikasikan ke komponen atau objek pencetakan. Dalam melakukan pengujian pengukuran dimensi penguji menggunakan alat ukur jangka sorong Krisbow KW06-422. Kemudian data hasil pengukuran diolah dengan metode Anova dengan bantuan software design expert version 10. Setelah dilakukan proses penelitian didapatkanlah hasil yaitu parameter yang paling berpengaruh adalah factor interaksi antara parameter exposure time dan parameter off time terhadap dimensi pada benda yang dicetak, dan kombinasi parameter yang paling optimal terdapat pada parameter exposure time 10 second dan off time 1 second dengan tingkat ketelitian sebesar 95%.

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