Additive Manufacturing of Reusable Moulds for Rapid Prototyping of Electrification Devices

The electrical equipment industry faces significant challenges in rapid prototyping due to high costs and extended lead times of traditional metal tooling for epoxy resin casting. This study systematically evaluates three additive manufacturing technologies (vat photopolymerization, selective laser sintering, and binder jetting sand printing) as alternatives for producing reusable moulds for vacuum casting of electrical insulation components. The research employs laboratory-scale characterization and industrial validation using medium-voltage current transformers. Surface roughness, dimensional accuracy, mould durability, and electrical performance were assessed. Results demonstrate that vat photopolymerization moulds deliver superior surface quality (Ra = 0.4÷0.9 µm) and durability (>12…