Additively Manufactured 2D Matrix Code Direct Part-Marking Casting Requirements

Direct part-markings (DPMs) can be formed into metal castings, using additively manufactured two-dimensional matrix encoded tags (AM2D) placed in a sand or shell mold. It has been unclear how thin a part can be and yet form a readable DPM. There must be sufficient molten metal to burn away the tag, and sufficient feeding pressure to form the 2D matrix code dot pattern. Here the formability limit for the casting of any AM2D (polymer) tag is shown to be the smallest heat energy from the latent heat of condensation needed to raise the temperature of the tag to ignition to burn the tag from the mold. The minimal part thickness that can be utilized is thereby derived. The minimum thickness is calculated to predict a part of various materials and compared positively with experiments. This provides a means to compute required part metal thickness to positively form a DPM tag before casting.