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Self-evolving experimental platform for 3D sand printing
Songtao Hu1, Xiantong Zhang1, Kaiming Tang1,2
1State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China.
National Science Review
|July 25, 2026
Summary
This study introduces Ex3D sand printing (Ex3DSP), an AI-powered platform that significantly reduces experimental workload for optimizing 3D sand printing processes. It enhances casting performance through intelligent experimentation and data-driven parameter selection.
Area of Science:
- Additive Manufacturing
- Materials Science
- Artificial Intelligence
Background:
- 3D sand printing faces complex optimization challenges due to numerous variables and conflicting objectives.
- Traditional methods struggle with the high-dimensional, nonlinear nature of casting mold fabrication.
Purpose of the Study:
- To develop a self-evolving experimental platform, Ex3D sand printing (Ex3DSP), integrating robotics and AI for optimized 3D sand printing.
- To address high-dimensional optimization problems in casting mold fabrication using an intelligent, 'do-while-thinking' paradigm.
Main Methods:
- Developed Ex3D sand printing (Ex3DSP), a platform combining robotic capabilities with AI cognition.
- Applied Ex3DSP to a three-objective, three-variable high-dimensional optimization problem in sand printing.
- Utilized a 'do-while-thinking' self-evolving experimentation paradigm.
Main Results:
- Achieved a 1148-fold reduction in experimental workload by discovering the Pareto front.
- Provided interpretable objective-optimal and balanced solutions.
- Revealed underlying mechanisms of variable-objective interaction and sand mold fracture behavior.
Conclusions:
- Ex3DSP demonstrates a novel self-evolving experimentation paradigm for 3D sand printing.
- The platform offers an intelligent additive manufacturing roadmap and potential for pre-industrial screening.
- Optimized casting parameters led to significant improvements (up to 385%) in physicochemical and mechanical performances.
