Rapid Prototyping Iron and Steel through Evaporative Casting Including Additive Manufacturing Patterns
Live event held on May 26, 2016

Presented by: Mark DeBruin, Skuld LLC
Sponsored by: TMS Materials Processing & Manufacturing Division (MPMD) and the TMS Additive Manufacturing Committee

Explore the benefits of a prototype made out of the actual materials of the final part, with lead times not much longer than conventional prototype methods. Join TMS for the new Rapid Prototyping Iron and Steel through Evaporative Casting Including Additive Manufacturing Patterns webinar—a part of the highly popular portfolio of TMS professional development events on additive manufacturing.

Topical Outline
Topics to be covered during this webinar include:
  • Review common additive manufacturing methods for metal
  • 3D printing used with conventional casting (3D printed sand molds and 3D printed wax)
  • Research into evaporative casting of 3D printed polymer
  • Design constraints of standard and 3D printed evaporative casting
  • Examples of evaporative cast prototypes with reduced lead time
Researchers continue to look to 3D printing to solve the problem of part customization, reduced lead time, and shape optimization. This webinar will show these are achievable not only through additive manufacturing, but through evaporative casting as well. Instructor Mark DeBruin will review the ability of conventional evaporative casting, or “lost foam,” to produce rapid prototypes and one-off designs at reduced lead time and which also permit shape optimization. This casting webinar will cover how this is done as well as the achievable design parameters for evaporative casting. This process differs from other casting methods in being able to do undercuts, backdrafts, blind holes, etc. while maintaining tolerances of up to 0.002” per inch. Research and success in utilizing steel in evaporative casting, including methods to produce low carbon alloys, are discussed.

A comparison is made of standard additive manufacturing techniques for metal components as well methods that use 3D printing in conjunction with conventional casting techniques (e.g., 3D printed sand molds and 3D printed wax for investment casting). Current research into transitive manufacturing, i.e. evaporative casting of 3D printed forms, including successful results in iron and steel will be covered. Failures which depict the limitations of this technology and areas for future research will also be discussed.


Design engineers, procurement professionals and those working in the supply chain, as well as those in aftermarket or prototyping will all benefit from attending this webinar.

Mark DeBruin has a bachelor’s degree in metallurgical engineering from The Ohio State University and a master’s degree in integrated mathematics from Kent State University. He has a breadth of experience that includes steel making, welding, machining, and heat treating. He has worked in casting since 1990 and has experience in casting ferrous and nonferrous alloys. He has worked with nearly all foundry processes including green sand, no bake, investment, and die casting, but his specialty is in lost foam casting. He has worked in nearly every aspect of foundries, from quality to procurement, from metallurgy to accounting. His experience includes working at three start-up foundries for others, and at his own company, Skuld LLC, which is working to commercialize a number of casting technologies. These technologies include: thin walled ductile iron technology, the steel “lost foam” casting process, surface alloying techniques, and, most recently, 3D transitive manufacturing where 3D printed polymer is converted directly into metal.

DeBruin is a Six Sigma Black Belt and has published a number of papers for the Society of Automotive Engineers, Society of Manufacturing Engineers, and the Association for Iron & Steel Technology. He also has a patent on selective carbidic outer-edge ductile iron product and the surface alloying process to create it.


The live webinar event was held on May 26, 2016, but the webinar recording is still available for purchase. Please note that after you purchase the webinar recording, you will receive an order confirmation e-mail from TMS. Please watch your inbox for a separate message from TMS Professional Development staff with information and links to access the webinar recording.

Registration Fees:
(Live Event or recorded event)
Member Rate $35
Nonmember Rate $55
Institutional/Group Rate $125