Rapid prototyping casting: the direct route to metallurgical precision
Accelerate your product development with the fully digitized workflow for rapid prototyping casting with Castfast. We use high-precision 3D sand printing to transform your designs directly into near-series metal components – across all materials, highly complex and ready to install.
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The digital evolution: high-speed rapid prototyping casting using 3D sand printing
Modern product development demands speed and flexibility. Castfast sets new standards in rapid prototyping casting through the consistent use of 3D sand printing. Instead of relying on physical molding equipment, we create your casting molds – including the most complex cores – directly from your CAD data.
This process significantly optimizes the time-to-market in the field of rapid prototyping casting. By building the molds using the layering process, we can complete projects in around two weeks, whereas conventional processes often take months. You gain valuable time for the validation and optimization of your assemblies without compromising on quality.
Complex geometries without design limits
With rapid prototyping casting, the digital workflow opens up completely new horizons for designers. As the mold is produced without tools, you can concentrate on the functional perfection of your component without having to take into account the limitations of classic molding processes:
Bionic structures
Implement lightweight construction strategies consistently. 3D sand printing enables organic shapes and optimized force curves that were previously considered impossible to cast. Topology-optimized components can save up to 40% in weight.
Integrated trunking systems
Realize precise cooling or media channels inside the casting during rapid prototyping casting with the highest surface quality and without additional assembly work.
Maximum depth of detail
The precise layer structure ensures excellent reproduction accuracy of logos, markings or functional surface structures – directly in the first cast.
Material validity: near-series results in rapid prototyping casting
A decisive advantage of Castfast is the material match between the prototype and the later series part. While other additive processes often rely on substitute materials, with rapid prototyping casting you get real metal from us.
Choose from over 200 alloys to test the exact mechanical properties of your design under real conditions. Whether high-strength ductile iron (EN-GJS) for dynamic loads, thermally resilient grey cast iron (EN-GJL) or specialized steel and aluminium alloys – you will receive a microstructure that corresponds exactly to the later series quality. Each component benefits from professional casting simulation, which ensures optimum solidification and microstructure formation during rapid prototyping casting.
Castfast ecosystem: Global network for rapid prototyping casting
Castfast acts as your central interface to a hand-picked network of leading European specialty foundries. Our intelligent matching system identifies in real time the partner in our network that has the optimal capacity and specific expertise for your rapid prototyping casting project order.
For you, this means maximum scalability and maximum supply security. Our workspace gives you full control over the production status, quality documentation and logistics processing at all times – all digitally transparent and from a single source.
Highest standards for maximum safety
We ensure your innovative strength through documented quality and in-depth metallurgical understanding in the field of rapid prototyping casting:
Foundry expertise
Our team is deeply rooted in the foundry industry and supports your rapid prototyping casting with in-depth expertise in solidification morphology and material selection.
Certified processes
Our partner foundries work according to strict industry standards and provide material test certificates in accordance with EN 10204 (e.g. 3.1).
Technical consulting
We support you in optimizing your data for casting in order to get the maximum functionality and cost-effectiveness out of your rapid prototyping casting design.
FAQ
How does 3D sand printing increase efficiency in rapid prototyping casting?
Using 3D sand printing (binder jetting), the molds are created directly from the digital design data. This enables immediate production without preparation times for physical mold making. The process is ideal for agile development processes in which fast iteration loops and a high degree of geometrical freedom are crucial.
What accuracies are possible with rapid prototyping casting?
The process delivers outstanding dimensional accuracy and surface quality that meets the requirements for high-quality mechanical engineering. In many cases, the precision of sand pressure in rapid prototyping casting even surpasses that of classic hollow mold casting.
Are the material properties of rapid prototyping castings comparable to series castings?
Yes, because the actual casting process is carried out with the same melts and under the same thermal conditions as in series production, the physical properties such as tensile strength, hardness and elongation are identical to the subsequent series product. It is a fully resilient component for real test scenarios.
