Micro-droplet injection forming technology demonstrates considerable potential with regard to additive manufacturing of complex casting sand molds. However, the influence of micro-droplet injection characteristics on the forming accuracy and injection regulation strategies is relatively weak during the process of promoting the industrialization of three-dimensional sand printing. Moreover, the practical requirements of precision rapid prototyping of complex sand molds have not been adequately addressed through investigations on the aforementioned influence. A jetting experiment platform is developed herein to optimize the driving waveform of a piezoelectric printhead. On the basis of theoretical simulations and experimental verification, the influence of the printhead waveform on its jetting characteristics is discussed. A method for driving the waveform is presented to improve and optimize the casting sand mold performance. Several case studies are presented to illustrate the effectiveness of the optimized driving waveform for enhancing the casting sand mold performance via systematic printing of a standard sand mold test block. Moreover, the optimal driving waveform’s contribution to the forming accuracy and efficiency of a large-scale casting sand mold is investigated through experiments using a three-dimensional sand printer. On the basis thereof, the effectiveness of the optimal driving waveform is demonstrated to improve not only the forming accuracy of the sand mold but also the production efficiency. This development can transform the industry of sand casting to produce high-quality castings.

微滴注射成型技术在复杂铸造砂模的增材制造方面显示出巨大潜力。然而，在促进三维砂印工业化的过程中，微滴注入特性对成形精度和注入调节策略的影响相对较弱。此外，通过对上述影响的研究，还没有充分满足复杂砂型模具的快速精密原型制作的实际要求。本文开发了喷射实验平台以优化压电打印头的驱动波形。在理论模拟和实验验证的基础上，讨论了打印头波形对其喷射特性的影响。提出了一种驱动波形的方法，以改善和优化型砂模具的性能。提出了几个案例研究，以说明优化的驱动波形通过系统打印标准砂型测试块来增强型砂型性能的有效性。此外，通过使用三维砂印机的实验，研究了最佳驱动波形对大型铸砂模具成型精度和效率的贡献。在此基础上，证明了最佳驱动波形的有效性不仅可以提高砂模的成型精度，而且可以提高生产效率。这一发展可以改变砂型铸造行业，从而生产出高质量的铸件。