Environmentally friendly and economical:Phenolic resin based 3D printing

This technology has already opened up a new possibility for the foundry industry, namely the fast and economic production of complex castings. Classic production processes show weaknesses or are reaching their limits. With 3D printing technology, whether for prototypes, individual parts or small series, seemingly impossible geometries can be produced quickly, precisely and cost-effectively. Speed and free design possibilities are the key features of this technology.

In addition, the use of large-format 3D printing systems and a wide range of materials for many sectors opens up more and more new possibilities for use. In the meantime, the technology is being used in the automobile industry for engineering, the pump industry and aviation.

A new material’s system using phenolic resin based binders offers advantages in terms of strength, recyclability, reduced gas consumption and environmental friendliness.

Economic production of prototypes and small series

Through the toolless production of sand moulds and sand cores, anything from individual parts to small series of several thousand parts can be produced economically. The complexity of forms and cores are no object for 3D printing, unlike conventional production. This is because the cost of 3D printing is not tied to the complexity of the component.

Firstly, undercuts and draft angles do not need to be considered. Secondly, necessary casting technologies such as gating systems can be constructed and communicated directly in the configuration. In addition, changes to components can be made flexibly, quickly and easily. The aim is to significantly reduce the time and costs involved in form and core production and to be able to economially produce complex geometries Therefore, a hybrid design combining 3D printing and conventional production can be used as an option.

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Advantages of phenol direct binding

In direct comparison, the new PDB process has many advantages over the conventional ODB process.

In the automobile industry in particular, sand cores are increasingly complex in their nature. Examples here are water jacket cores, hydraulic components or costly exhaust manifold cores. We have already seen increased bending strength from the printed PDB parts (250-500 N/cm² – strength based on the orientation in the assembly space) over ODB parts (230-330 N/cm² – strength based on the orientation in the assembly room).

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