This article presents an approach to making an aluminum automobile prototype by integrating numerical simulation and rapid prototyping into investment casting. Following the integrated prototype procedure, a sound aluminum (Al-Si-7Mg) manifold prototype with excellent contour and an accept-able surface finish was made with only one casting trial. This study indicated that the potential of the rapid prototyping-invest ment casting coupling could be more effective with the aid of integrated numerical simulation, and numerical optimization of the casting parameters aids in minimizing the risk of casting failure and avoiding the iterative casting trials.
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