There has been a gradual adoption of Three-Dimensional (3D)
printing in pattern making for sand casting absolutely because of its reduced lead-time and higher dimensional accuracy.Pattern making is the most central activity in the production line of any casting operation. A delay in pattern making or a defect in pattern usually translates to increased production cost and time or poor quality castings respectively. Many foundry industries have been concerned with reducing the duration for pattern making and improving the dimensional accuracy of patterns. Adoption of Fused Deposition Modeling (FDM) based patterns have only provided a limited solution to the challenges of traditional pattern making for sand casting.Some patterns are not suitable for FDM printing due to their size volume which is not usually cost-effective to print. Also,the surface quality and mechanical properties of patterns produced with FDM are usually affected by process parameters thereby leading to post-manufacturing treatment before the patterns are suitable for moulding operation. This study investigated the problems of traditional pattern making and the challenges of FDM-printed PLA-patterns for sand casting and suggested solutions and areas for future research. Related researches on 3D printing in the foundry carried out around the worldwide are discussed
