Liberty Pattern Company (LPC) has been a trusted name in the tooling and patternmaking industry in the US for over four decades. LPC specializes in producing complex mold and core geometries for demanding industries such as aerospace, e.g. for flight-critical components like gearboxes. Their full-service patternshop capabilities range from reverse engineering and CAD design all the way to part machining. However, what sets LPC apart today is its bold move into additive manufacturing. Among their fleet of 3D printers also range three voxeljet VX1000 3D sand printers with the unique Phenolic Direct Binding (PDB) process.
Driving Forces Behind the Shift to Additive Manufacturing from Prototyping to Serial Production
Liberty Pattern began exploring 3D sand printing in 2017 to meet growing customer demand and internal needs for speed, precision, and prototyping flexibility. “We saw an opportunity to help our customers leverage the technology — and it paid off,” says Rick August, Vice President – Additive Sand Solutions at LPC. “Since the initial setup, additive manufacturing has become a daily operation for us and today is deeply integrated into both prototyping and serial production workflows.”
For a service bureau like LPC, the ability to offer rapid iteration, validation of gating systems, core consolidation and even full-scale production was a true game changer. Traditional sand tooling, while still relevant, couldn’t compete with the speed to metal and design freedom offered by additive manufacturing.
Why voxeljet? Precision, Performance and Phenolic Binding
While LPC operates several 3D printers for molds and cores, voxeljet is currently the only provider that meets their requirements for Phenolic Direct Binding (PDB) – a decisive factor in expanding the range of applications they can serve. PDB works by spreading a thin layer of raw printing medium — in this case, sand — and selectively jetting a phenolic binder into the desired areas. Infrared energy is then applied to the build platform, triggering a reaction that cures and solidifies the printed regions, while the unbound sand remains loose and 100 % recyclable.
We saw an opportunity to help our customers leverage the technology — and it paid off
Rick AugustVice President Additive Sand Solutions, Liberty Pattern Company
The voxeljet VX1000 printer, equipped with PDB technology, allows LPC to print high-strength cores using Carbo ceramic media, a U.S.-sourced sand with superior thermal stability and mechanical properties. “Carbo’s improved media qualities and low thermal expansion are ideal for our demanding applications,” explains August. Paired with phenolic binding, it ensures exceptional strength, making printed cores resilient during casting – especially critical when working with metals like aluminum, magnesium and iron. This significantly lowers the risk of casting defects, minimizes costly rework, and boosts first-pass yield.
Sustainability and Cost Efficiency through Recyclability
A major sustainability and cost advantage of voxeljet’s solution lies in its high recycling rate. LPC continuously recycles unprinted Carbo media — only requiring simple sieving before reuse. This not only reduces material waste and costs but also supports environmentally responsible manufacturing practices.
Scalability and Redundancy for Continuous Production
After the success of the first installed VX1000 – ordered and installed in 2024 – Liberty Pattern now added a second and third unit in 2025 to expand capacity, introduce redundancy, and ensure uninterrupted operations. “Now, if one machine goes down or is undergoing maintenance, production doesn’t stop,” says August. This investment lets LPC handle large-volume production, multiple simultaneous projects, and reduce lead times, especially during peak demand.
With all printers operating, LPC can produce parts across a wide range of sizes — from small prototypes to larger cores for casting, printed in single runs with the VX1000’s build volume of 1000 × 600 × 500 mm.
Customer-Centric Value Creation
Liberty Pattern leverages voxeljet’s technology to deliver significant value to their industrial clients:
Faster Turnaround:
3D printed cores drastically reduce tooling and lead times.
Increased Flexibility:
Rapid iteration and design changes without retooling.
Gating Validation:
Quick testing of gating sytems and riser designs before full-scale production.
High Strength:
Phenolic binding supports robust casting, even for intricate geometries.
Sustainable Production:
High recycling rate of unprinted media reduces waste and cost.
Looking Forward: Building on a Foundation of Precision
As many industries, but the aerospace especially, continue to demand lighter, stronger, and more complex components, Liberty Pattern is poised to lead – combining traditional craftsmanship with modern digital manufacturing.
Rick August envisions even broader applications of 3D printing in the near future: “We’re looking forward to faster print speeds and improved surface finishes. Additive manufacturing is absolutely part of our future — for prototyping, validation, and full production.”
Liberty Pattern Company’s integration of additive manufacturing in general and voxeljet’s VX1000 with PDB technology in specific, exemplifies the transformative impact of this technology. By combining material innovation, environmental responsibility, and operational agility, LPC has elevated its offering — enabling industry customers to achieve better castings, faster.
