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Freedom, freedom! How 3D sand printing is pushing the boundaries of casting design

Discover how 3D sand printing in casting design overcomes traditional limitations and enables complex, cost-effective designs. Learn more about the benefits of this innovative technique, from print-ready core packages to unlimited design freedom.

Designers know this: The many advantages of cast parts have so far been accompanied by restrictions in terms of design freedom. Although the permanent wooden model required for traditional mold production can reproduce the later component contour very accurately, it must be possible to shape it, which sets clear limits to the design possibilities.

Uncompromisingly complex castings

In casting with a permanent pattern, component complexity is achieved with mercilessly complex, multi-part patterns and core packages made up of segments.
With high-tech cast parts, the classic process quickly results in core boxes consisting of dozens of parts that have to be connected and handled manually. At the end of the day, the reward for all this effort is that you can cast exactly one design variant of the component. Make a quick change? Impossible.
With 3D sand printing, entire core packages are printed directly, with almost no additional effort. Sand printing does not require core boxes either. Mold segments are printed in larger sections.

Form follows function – finally

For developers and designers, all this means that the design of the component can finally take place free of manufacturing considerations – whether economic or technical. In terms of the limits of production technology: 3D sand printing can handle undercuts and does not require bevels. The shape does not always have to be split either.
This dramatically expands the design possibilities. Surfaces can be radically optimized and functions integrated. Filigree internal geometries and bionic structures are suddenly feasible. Weight reduction and component optimization become child’s play.



Complex components are no longer a problem thanks to our 3D sand printing!

Several design variations in one go

Whether in product development or in the design of special parts, sometimes several variations of a cast part have to be produced. This is difficult with a model. Not with 3D sand printing. The mold is only created on the basis of a digital print file. This can be changed and varied as often as required.

To adapt the flange on a spare part or to produce and compare many design iterations at the same time during development. The shrinkage dimension can also be easily adjusted to cast the same component in a different material.

Conclusion

The speed, precision and cost benefits of 3D sand printing are also effective when a cast part is manufactured unchanged using the new process. However, many more possibilities open up when designers can simply ignore the usual manufacturing considerations when designing components. Then completely new, better cast parts are possible. Structures and surfaces can be reimagined. Freedom, after all.

The CASTFAST team will be happy to help you explore 3D sand printing for your application.

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