3D printingsaves up to 75%in sand casting costs

3D printing brings time and cost saving advantages when compared to conventional manufacturing. In direct comparison to conventional production, 3D printing illustrates a clear cost profit. When the production in conventional production lies at around 3,600 € the production with 3D printing can be reduced to 900 €.

3D printing does not only help save costs, as illustrated, but it also helps dramatically shorten the production process for molds and cores. Entire steps, including expensive tool costs, among other things, can be eliminated, since only one CAD data set is needed to produce sand molds and cores.

3d printed impella from voxeljet

Economical production, from prototypes to small batches

Short delivery times and a high degree of flexibility play a crucial role in meeting a wide range of requirements. But how do we link these two factors reasonably and, most importantly, economically?

From printed core to finished cast part

Blacking Like with classic sand casting, the printed core is also provided with a black wash in the foundry so that it can withstand the high thermal loads.

Mounting the core The 3D-printed sand core is subsequently inserted into a conventionally produced mold. Conventional production methods and 3D printing can generally be combined at will.

Casting The turbine wheel is now cast. All common alloys can be cast with the 3D-printed molds and/or cores. Different sand granulations can be used to influence the surface quality.

Removing the core Like with conventional production methods, 3D printing of sand molds and cores is a lost-mold casting method.

Post-processing The component is post-processed after it is removed from the mold. The amount of post-processing work required is reduced by the 3D printing process, since cast parts are already more accurate. This is due to the fact that even complex geometries with undercuts can be printed as a single piece.

Benefits of 3D printing at a glance

  • Time savings and cost savings with short throughput times and tool-free production.
  • High flexibility in terms of number of pieces and mold design.
  • Hybrid design by means of combination with conventional processes.
  • No storage & maintenance costs for conventional sand molds and sand cores.

Further Case Studies


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