volumecasting

Volumecasting is a class of casting methods in which the geometry of the final part is derived from volumetric representations, such as voxel grids or three-dimensional scalar fields, rather than from traditional surface-based patterns. In volumecasting, a mold or pattern is produced directly from the volume data and then used to shape a liquid or malleable material into the desired object. This approach is especially suited to reproducing complex interior features, porous networks, or gradient materials that are difficult to realize with conventional patterns.

The typical workflow begins with obtaining volumetric data from sources such as CT or MRI scans, CAD voxelization, or computational simulations. The volume is processed to define a mold or core and then translated into tooling via additive manufacturing or subtractive methods. A mold is created (for example, by 3D printing a solid insert or by fabricating a sacrificial core) and the casting material—metal, polymer, or ceramic—is introduced and allowed to solidify. In some implementations, the volume is cast directly into a dissolvable container or through a multi-material process that fills a lattice or channel network.

Volumecasting enables rapid prototyping of complex geometries, internal channels, and graded properties without the need for traditional wax models or pattern assembly. It can reduce tooling steps and shorten lead times but may require specialized molds capable of withstanding thermal or chemical interactions and dealing with shrinkage and demolding. The accuracy depends on the voxel resolution, the material's shrinkage, and the fidelity of mold fabrication.

Applications span medical modeling, aerospace tooling with integrated cooling channels, architectural art, and functional components that benefit from intricate internal features and material gradients. See also: casting, rapid prototyping, voxel, voxelization, additive manufacturing.