Technology Redefined: The Advantages of the Sand Printing Process in Modern Casting Production

Efficiency Through Large Build Volumes and High Printing Speeds

One of the primary benefits of the sand printing process is the large build volumes. On a construction platform measuring 1800 x 1000 x 700 millimeters, we can print large-scale sand molds and cores. Utilizing our four printers from the manufacturer ExOne, as well as the high printing speeds, we ensure fast and reliable part delivery. This is particularly advantageous for time-sensitive prototype projects, as development cycles are significantly shortened. 

Realizing Complex Geometries and Undercuts

The 3D printing of mold materials allows for virtually unlimited design possibilities. Even highly complex shapes with undercuts and delicate details can be produced. This design freedom opens up entirely new possibilities for optimizing and shaping components that would be challenging to achieve with traditional methods. 

Removing the unbound mold material from the mold parts remains a limitation of the process. This led us to develop our own finishing method. With this proprietary technology, even intricate internal contours can be safely cleaned, further expanding the application possibilities of 3D printing in the foundry sector. 

Cost-Effectiveness and Sustainability

Compared to other 3D printing techniques, the sand printing process is characterized by its high cost-effectiveness. Since complex tooling is not required, the costs associated with tool fabrication are eliminated. This allows for the implementation of load-optimized, material-efficient designs. 

The reduction in mold splitting decreases post-processing efforts. Integrated sand recycling and reduced logistical operations also contribute to sustainability, enabling us to provide more environmentally friendly solutions. The process is not only cost-efficient but also ecologically beneficial. 

Precision and Superior Surface Quality

By using sand layers approximately 300 micrometers thin, very high accuracy and excellent surface quality are achieved. This significantly reduces the need for subsequent processing and enables the production of high-quality cast parts that meet the highest standards. 

Versatility and Combination Possibilities

The 3D-printed mold material is suitable for casting many metals, including aluminum, gray iron, and steel. A variety of binder systems and mold materials are used. Additionally, the printed cores can be combined with conventionally manufactured sand molds, offering high flexibility for executing both classic prototype projects and small series. 

This process revolutionizes the production of casting molds through its ability to efficiently and precisely realize complex geometries. Thanks to its numerous technological advantages, the sand printing process has completely replaced our previous additive mold manufacturing process, the laser sintering of molded parts. 

The combination of large build volumes, high printing speeds, cost-effectiveness, and sustainability makes this process an essential solution for modern casting production. 

Would you also like to benefit from the advantages of the sandprint process? Then rely on us to successfully realize your next project. Our technical sales team will be happy to support you!

On our industry-specific pages you will find numerous projects that have already been successfully realized at ACTech using the sand printing process.

ACTech – Your Partner for Innovative Casting Production.