Cellular materials offer high strength accompanied by low-density and can offer high
stiffness, good impact-absorption, and thermal and acoustic insulation. In this paper, the authors
describe their progress towards exploring the use of metal casting into 3D printed sand molds for
creating cellular materials and sandwich panels. The use of 3D printing allows for the
fabrication of sand molds without the need for a pattern, and thus enables the creation of cellular
structures with designed mesostructure from a bevy of metal alloys. The quality-of-fill results
for several cast aluminum cellular parts of varying geometry are presented in this paper, along
with a discussion of overall truss diameter variation.Mechanical Engineerin
