Additive manufacturing (AM) processes are used to fabricate three-dimensional complex geometries. There are several technologies that use laser or electron beam over metal powder beds. However, the direct AM processes have inconveniences such as specific set of materials, high thermal stress traced, high local energy absorbed, poor surface finish, anisotropic properties, high cost of material powder, and manufacturing with high-power beams. In this paper, an alternative process was developed. An indirect additive manufacturing (I-AM) combining a 3D print of castable resin and metal casting in order to obtain a cellular structure similar in shape to commercial metal foams but completely definable as design features was developed. Design of the cellular structure was made by the graphical algorithm editor Grasshopper®. Designed structures were realized by a lost-wax casting process and compared with commercial foam specimens by a system designed for this work. The designed metal foams showed a performance superior to that of commercial metal foam; in particular, the heat thermal coefficient of designed metal foams in the better case was 870 W/m2·K, almost doubled in comparison with the commercial foam tested in this work.
Keywords: additive manufacturing; metal foam; open cell; random structure; thermal test.