Friedberg near Augsburg, Germany, June 2021 – To develop the new high-performance ceramic material set Brightorb^TM for 3D printing, AGC Ceramics Co., Ltd. has entered into a cooperation with voxeljet AG from Friedberg in Bavaria, Germany. Brightorb was developed on a VX1000 with a build volume of 1000 x 600 x 500 mm. The 3D printing system works layer-based and bonds the ceramic particles with an inorganic binder. Targeted applications for the new, ceramic material set include high-performance cores for sand and investment casting, ceramic filters, structural components, as well as art and product design.

The ceramics material with its brand name Brightorb is composed of spherical sand with the main components Aluminum Oxide (Al2O3) 80%, Zirconium Oxide (ZrO2) 10%, Silicon Oxide (SiO2) 9%, the minerals Corundum, Baddeleyite and kinds of cement. During 3D printing, Brightorb is applied to the build platform with average grain sizes of 50 µm and layer thicknesses of 100 µm and selectively bonded with an inorganic binder. The inorganic binder is characterized by its high environmental compatibility as only water vapor is produced during molding. This greatly improves environmental and working conditions in foundries. To subsequently prepare the printed ceramic for the final application, the printed components get impregnated by a silica-based liquid and have to be fired in a sintering furnace for their final strength. Most of the unprinted powder can be reprocessed, recycled and fed back into the printing process.

“We have been noticing a growing demand for increasingly complex component geometries among our customers for a long time,” explains Dr. Ingo Ederer, CEO at voxeljet. “The great advantage of the geometric freedom of 3D printing is, that geometric adjustments can significantly optimize the efficiency and effectiveness of, for example, engines or turbine wheels. It is rare that such complex components can still be produced using conventional molding processes. Together with AGCC, we have been able to optimize a VX1000 for ceramic powder in close cooperation, so that it is ideally suited for the challenging demands of metal casting. Both in terms of strength and surface quality”, says Dr. Ederer.

The 3D-printed ceramics are used, for example, as cores for the investment casting process in order to reproduce complex and filigree cavities within castings. In this process, the filigree cores are combined with conventional wax patterns. These are coated with a ceramic slurry and burned out before casting. What remains is a hollow ceramic mold in which the printed core is still inserted. Molten metal is then poured into the mold. After cooling, both the mold and the core are removed.

This process makes it possible, for example, to integrate internal cooling channels in turbine blades, thus increasing turbine efficiency and reducing downtimes to a minimum. Mr. Ushimaru, Additive Manufacturing Director from AGCC is also satisfied: “Brightorb is a high-performance ceramic that is extremely well suited for metal casting due to its high-chemical stability, heat resistance, thermal conductivity and low thermal expansion. We were able to optimize the material set in such a way that the shrinkage factor of the printed components during the downstream sintering process at 1,400°C is less than 1%. This means that the components are also suitable for filigree core designs. Thanks to the high-fire resistance, it is possible to cast alloys with melting points beyond 1,600°C. Overall, ceramics will continue to gain importance as a material in the future, and the same applies to 3D printing as a manufacturing technology. We are pleased to have embarked on this path together with voxeljet and look forward to further close cooperation.”

News highlights

• Three additional VJET X high-speed 3D printers were ordered recently: 1 VJET X unit in August 2020 and 2 VJET X units in September 2020
• The follow-up order comes as part of a frame contract concluded in 2018 between voxeljet, its partners and a leading German carmaker. The first two VJET X units were ordered in mid-2018. This follow-up order brings the current total to 5 VJET X units for this OEM
• The follow-up order reaffirms voxeljet’ s message that its new 3D printers are making additive, serial production possible and cost-efficient
• VJET X 3D printers are 10x faster than previous models, which results in a layering speed close to 5 seconds and are integrated into fully automated postprocessing solutions
• The 3D printers use an environmentally friendly inorganic binder system for zero emissions during core printing, storage and when using the sand cores in the casting process

voxeljet AG (NASDAQ: VJET) (the “Company”, or “voxeljet”), a leading provider of high-speed, large-format 3D printers and on-demand parts services to industrial and commercial customers, announced last week that it received the follow-up order for three additional units of its new high-speed 3D printer VJET X over the last two months. VJET X 3D printers are made for industrial production: they are 10x faster than previous models and integrated into fully automated postprocessing solutions. The follow-up order comes as part of a frame contract concluded in 2018 between voxeljet, its partners and a leading German car maker.

This follow-up order is a significant milestone in VJETs mission to bring 3D printing into high-volume, industrial production and reaffirms the Company’s message that its new 3D printers are making high-volume industrial production possible and cost efficient.

Dr. Ingo Ederer, founder and CEO of voxeljet commented: “With this order we reached a significant milestone in our mission to bring 3D printing into high-volume industrial production. This is extremely exciting, as it not only highlights the significance of our technology, but also the confidence this leading German car maker has in the new solution and the players behind it. Together with our partners, we can today offer a solution for the mass production of complex sand cores for light metal parts at, what we believe to be, a fraction of the costs as compared to other players in the additive manufacturing industry. With the new environmental-friendly binder system, there are zero emissions during the casting of the sand cores. The casted, complex light-metal parts can have superior characteristics, such as less weight and new features, and can ultimately help to reduce CO2 emissions substantially.”

Friedberg – voxeljet AG is delighted with yet another sale of its VX4000 3D sand printer to one of the largest foundries in western India. The VX4000 is among the world’s biggest binder-jetting systems for industrial production, with a build volume of eight cubic meters (4 x 2 x 1 m).

“voxeljet has been active in India for almost ten years and of late we are seeing a paradigm shift with foundries focusing on technology to drive growth. Our customers in India started with ordering on-demand printing services for critical projects and over time gained confidence in 3D printing technology and voxeljet.”, says Rudolf Franz, COO & CFO voxeljet AG.

All current Indian system customers invested in the technology with varied end goals, for example:

• Easy and quick diversification of the business
• Manufacture multi-ton single piece castings without the need for tooling
• Quick prototype castings to gain production business
• Bridge castings while the tooling is on its way
• Mass production of critical cores
• Cater to the growing aerospace business in India

“In the last couple of years, the government of India has pushed its ‘Make in India’ initiative, thereby encouraging businesses to invest into the future. For our customers in India, it was clear that adopting new technologies would help them benchmark against international standards and fuel growth.”, says Nidhi Shah, Managing Director voxeljet India Pvt Ltd and adds:

“In India there is also a growing trend towards IoT to fine tune processes, save energy and save costs and push towards automation wherever possible. One of the intangible benefits of this development has been a change in brand image of the foundry industry in India, which means they can attract and retain talent with Additive Casting.”

With these advancements, the Indian foundry industry has positioned itself to take on new businesses, domestic as well as international.

“The Indian market has always been interesting for voxeljet as it comes with immense opportunities. We have seen the foundry industry grow in India, not only in terms of Tonnage Per Annum (TPA) but also in terms of manufacturing of quality of castings. The recent sales of our largest 3D printers to clients in India is a testament to growth, and we are excited to be a part of the Indian foundries’ growth story. We believe in the strong potential of Additive Casting in India and are looking forward to future projects.” says Rudolf Franz.

Friedberg – voxeljet AG, a leading global technology company for industrial 3D printing solutions, is delighted to further expand its presence in India. The Indian steel casting expert Peekay Steel Castings (P) Ltd has decided to invest in the VX4000, with a Job Box size of 4000 x 2000 x 1000mm. The VX4000 system is one of the world’s largest and most productive 3D printers with a build volume of eight cubic meters and a print speed of 54 hours for one full job box. Peekay Steel has chosen the VX4000 system to quickly and economically realize technically demanding projects and to expand into new business areas.

Peekay Steel specializes in the production of high-quality steel castings, predominantly for the Oil & Gas sector, starting from 1 kg to 20 tons per casting. For most of these products they require less than four castings.  As a result, the time and cost towards development of patterns can outweigh total project costs. For some complicated castings, that require non-traditional gating, the VX4000 was most suitable.

“When it comes to castings weighing several tons, the requirements for dimensional stability and accuracy are particularly high. With our 20 years of experience in the field of industrial 3D printing and the VX4000, we can offer both a wealth of experience and the right tool. With another VX4000 installation in India, we look forward to continuing our cooperation with Peekay Steel,” says Rudolf Franz, COO & CFO of voxeljet AG.

“We want to offer our customers an end-to-end solution and position ourselves as a supplier of high-quality, ready-to-install components in record times. With the VX4000, we are able to increase the flexibility of our production in order to be able to react quickly, even to complex projects. 3D printing gives us a unique competitive advantage, especially when it comes to expanding our business areas.  Since the beginning, we have emphasized the importance of co engineering with our customers, most of these are Fortune 500 companies, to optimize and customize the product design, to lend better functionality and a clear competitive advantage. A specialized Design Center aligned to the VX4000 will help add value for our customers,” adds K.E. Shanavaz, Jt. Managing Director, Peekay Steel Castings (P) Ltd.

Additionally, one of the drivers was the impending uncertainty in these trying times. With the size, speed and flexibility of the VX4000 Peekay Steel can cater to new projects from their existing customers at record times while also looking for different business areas to venture into.

Peekay Steel has a multi-pronged approach to their VX4000. They not only want to support the foundry industry in India by providing services from their large system, but also plan to set up a high-tech Knowledge Center around their VX4000.  This will include a training facility to support educational institutes and the industry alike.  An open access of this kind is a means to attract more and more people towards the foundry industry- a much needed paradigm shift.

voxeljet has offered its capacities in its 3D service centers in the following initiatives:

• Siemens ANM: Connecting 3D Print Services to Fight COVID-19
• Medical goes Additive: 3D printing fights Corona

Amongst others, first deliveries such as mounts for protective visors to the emergency ward of the hospital here in Bavaria have already taken place. Should you also have a need for such equipment, please feel free to contact us through the above mentioned initiatives or directly via Mail. We would like to take this opportunity to thank Siemens, Mobility goes Additive and Evonik, who are actively supporting us with their expertise and materials.