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3D sand printing as a savior in times of need: three practical examples

Rapid casting procurement is often still based on long-term relationships with suppliers and good preparation. When something unforeseen happens and it has to be done quickly, the disadvantages of traditional casting with a wooden model become a problem. 3D sand printing can step in in such situations. Here are three examples from CastFast production where Printed Casting has helped customers out of a tight spot and made the impossible possible.
3D sand printing can step in in such situations. Here are three examples from CastFast production where Printed Casting has helped customers out of a tight spot and made the impossible possible.

Oh shock, oh shock, the model is gone!

 

The situation

A milling head breaks at a customer of a manufacturer of large machine tools, causing downtime. A replacement part is urgently needed.  

The problem

The old wooden model of the cast milling head can no longer be found.  

The solution

CASTFAST steps in and delivers the casting within a very short time. The print file for the sand mold was created on the basis of drawings.

Component profile

Milling head
  • Quantity: 1
  • Weight: 350 kg
  • Material: EN-GJS-400-15U
  • Delivery time: 4 weeks

Unimaginable: going to the trade fair without a new product?

 

The situation

A manufacturer of innovative precision lathes wants to take its latest development to a trade fair.

The problem

Production of the new development has not yet started. Models for cast components have not yet been built.  

The solution

CASTFAST can deliver the parts for the trade fair machine on time. The high precision of the 3D sand printing process means that less machining is required. 3D sand printing also enables a faster start to series production, as the model construction time can be bridged.

Component profile

Lathe parts, including headstock, spindle housing, X-, Y-, Z-slides, small parts
  • Quantity: 24 different parts
  • Material: EN-GJL-300
  • Delivery time: 5 weeks

When misfortune draws circles: Supplier insolvency

 

The situation

A manufacturer of special machines loses its casting supplier due to sudden insolvency.  

The problem

Urgently needed machine parts have to be sourced from a new supplier at lightning speed.  

The solution

CASTFAST creates the sand molds based on CAD data of the required components, completely without a model. These are cast and delivered in the same way as traditionally manufactured molds. Project deadlines can be met despite supplier insolvency.

Component profile

X-slide, swivel bearing
  • Quantity: 4 pieces each
  • Weight: 75 kg, 90 kg
  • Material: EN-GJL 250 and EN-GJS 500-7
  • Delivery time: 4 weeks

The new emergency center for cast parts is called castfast.de – with instant quotes and online ordering for urgently needed cast parts. Helps even when there’s no fire!
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Printed castings are not only faster out of the starting blocks. The 3D sand printing process accelerates cast part production in several areas. From the iterative optimization of the component and mould design and the integration of mould components into a single piece, to reduced post-processing - 3D sand printing enables a sprint from CAD file to finished component in days or a few weeks, not months. And testing is also faster, thanks to the online calculator and digital ordering process.

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