In which application does using AM as a secondary process require a significant time and resource investment due to the destruction of the AM part?

The use of additive manufacturing (AM) to produce sacrificial patterns for investment casting indeed requires significant time and resource investment due to the nature of the process. In this application, AM is employed to create patterns that will be destroyed during the casting process. This investment is not just in the materials and the AM process itself, but also in the post-processing steps needed to ensure that the pattern achieves the desired surface finish and dimensions.

In investment casting, these patterns are often made from materials like polymers that can be melted away when the molten metal is introduced to the mold. Since the purpose of creating these patterns is inherently temporary—to serve as a mold and then be removed—there is a clear understanding that the AM part will be destroyed. The time and resources spent on this can include the costs of AM equipment, specialized materials, skilled labor for finishing, and the added complexity of ensuring that the pattern meets all specifications for the final cast part.

In contrast, applications such as creating spare parts or fabricating prototypes typically focus on producing functional components that can be used directly without the destruction of the part. While developing tooling for traditional manufacturing can involve significant investment, it doesn't end with the destruction of the AM part in the same way that sacrificial patterns do. Thus