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Pattern making in sand casting process is specter problem since it is very consuming in time and cost. 3D printing technology which increases remarkably is the answer to the troubles of pattern making in sand casting. In this study, a product model of intake manifold made by sand casting and the pattern developed using stereolithography (SLA) 3D printing technique. The research and development of a PPE (planning, production, and evaluation) method was implemented to developing the pattern. A model of intake manifold was made by method of 3D printing technique which done on Anycubic Photon Mono X printer using Anycubic basic ultraviolet resin. The best position configuration are X = -45°/45°, Y = 45°/-45°, Z = -5 mm and exposure time of 6 seconds. The maximum dimension deviation of the pattern was 0.02 mm which is smaller than the thickness of layer height of 0.05 mm. The plate pattern was easier to make which save a lot of time. The SLA 3D printing also simplifies the making of core box and sand core. This is impacting on the making of mold sand and the casting product quality. The surface smoothness, geometry goodness, and dimension precision of sand mold will affect directly on casting product. This is proven by the casting maximum product shrinkage of 0.55% or 0.20 mm. The good geometry and shape of casting product were also obtained [ABSTRACT FROM AUTHOR]

Innovation on a crucible furnace to increase its efficiency in aluminum melting has been done. The innovation was a spiral finned crucible pot. The inclination of the spiral finned was vary of 5, 10, 15, and 20 degrees. The spiral finned effects was determined from the performance test result. A crucible pot without fin was also tested as a control. The crucible pot was examined at the same process condition. The crucible pot with the inclined fin of 10 degrees gives an optimum performance. It gives effective heating rate so that more efficient in LPG consumption. Therefore it saves energy in the aluminum melting process. [ABSTRACT FROM AUTHOR]