“Printed Casting” and “Digital Warehouse” are now a real alternative to hollow-mould-casting with wooden patterns.
The production of small casting series in hand-mould-casting with wooden patterns is becoming increasingly uneconomical and is the cause of the disappearance of many foundries in the weight range up to 10,000 kg. This means that it is hardly possible to achieve adequate prices and quantities on the market.
Meanwhile, “printed casting” offers a real alternative. Here, the sand moulds and cores are produced directly in a 3D sand printer and cast with the desired casting material, be it iron, steel, aluminium alloys or copper, even for unit weights of several tonnes. Models are no longer needed. Customers either provide the 3D data set of the desired casting or have the foundryman digitise a corresponding data set from 2D drawings. Castings for which no data is available at all can be created by reverse engineering, i.e. digital measurement with a scan and feedback as a 3D data set. The casting can then be produced in a few days with the data from the “digital warehouse”. Even after many years, virtually at the touch of a button with just a few clicks. This makes it very easy to digitise tool and model inventories. Especially the models for spare parts or castings that are only rarely in demand.
The production of wooden models and their storage with usually high demands on environmental conditions is thus completely eliminated. There are also no more costs for storage rent, insurance and the preservation of the sensitive wooden models. At the same time, “Printed Casting” gives you new additional freedom. Castings can be changed at any time, because only one data set needs to be adjusted. And geometries are possible where classical models reach their limits, for example in the implementation of topology-optimised components.
Compared to classic hollow-mould-casting, “Printed Casting” offers a number of other advantages in addition to the short delivery times, the elimination of the wooden model including expensive storage costs and storage logistics: In series production, there are no longer any dimensional deviations from piece to piece, for example due to the wear of the wooden model. The delivery rhythm is no longer interrupted by model repairs.
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