{"id":5194,"date":"2024-03-18T17:58:28","date_gmt":"2024-03-18T16:58:28","guid":{"rendered":"https:\/\/web.castfast.com\/2024\/03\/18\/highly-complex-from-a-standing-start\/"},"modified":"2025-05-26T11:51:00","modified_gmt":"2025-05-26T09:51:00","slug":"highly-complex-from-a-standing-start","status":"publish","type":"post","link":"https:\/\/www.castfast.com\/en\/2024\/03\/18\/highly-complex-from-a-standing-start\/","title":{"rendered":"Highly complex, from a standing start"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"5194\" class=\"elementor elementor-5194 elementor-1263\" data-elementor-post-type=\"post\">\n\t\t\t\t<div class=\"elementor-element elementor-element-b1986e2 e-con-full e-flex e-con e-parent\" data-id=\"b1986e2\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-324555fb elementor-widget elementor-widget-theme-post-featured-image elementor-widget-image\" data-id=\"324555fb\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"theme-post-featured-image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img fetchpriority=\"high\" decoding=\"async\" width=\"1907\" height=\"1551\" src=\"https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/03\/01-Banner-scaled-e1710781688407-jpg.webp\" class=\"attachment-full size-full wp-image-4924 not-transparent\" alt=\"\" srcset=\"https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/03\/01-Banner-scaled-e1710781688407-jpg.webp 1907w, https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/03\/01-Banner-scaled-e1710781688407-300x244.webp 300w, https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/03\/01-Banner-scaled-e1710781688407-1024x833.webp 1024w, https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/03\/01-Banner-scaled-e1710781688407-768x625.webp 768w, https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/03\/01-Banner-scaled-e1710781688407-1536x1249.webp 1536w\" sizes=\"(max-width: 1907px) 100vw, 1907px\" data-has-transparency=\"false\" data-dominant-color=\"555552\" style=\"--dominant-color: #555552\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-a4f9270 e-con-full e-flex e-con e-child\" data-id=\"a4f9270\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;background_background&quot;:&quot;classic&quot;}\">\n\t\t\t\t<div class=\"elementor-element elementor-element-73b105a6 elementor-widget elementor-widget-theme-post-title elementor-page-title elementor-widget-heading\" data-id=\"73b105a6\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"theme-post-title.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h1 class=\"elementor-heading-title elementor-size-default\">Highly complex, from a standing start<\/h1>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-4ff5d225 elementor-align-center elementor-widget elementor-widget-post-info\" data-id=\"4ff5d225\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"post-info.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<ul class=\"elementor-inline-items elementor-icon-list-items elementor-post-info\">\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item elementor-repeater-item-7f530f1 elementor-inline-item\" itemprop=\"datePublished\">\n\t\t\t\t\t\t<a href=\"https:\/\/www.castfast.com\/en\/2024\/03\/18\/\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text elementor-post-info__item elementor-post-info__item--type-date\">\n\t\t\t\t\t\t\t\t\t\t<time>March 18, 2024<\/time>\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t<\/li>\n\t\t\t\t<li class=\"elementor-icon-list-item elementor-repeater-item-6863c75 elementor-inline-item\" itemprop=\"author\">\n\t\t\t\t\t\t<a href=\"https:\/\/www.castfast.com\/en\/author\/marcel\/\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text elementor-post-info__item elementor-post-info__item--type-author\">\n\t\t\t\t\t\t\t\t\t\tMarcel Tschillaev\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t<\/li>\n\t\t\t\t<li class=\"elementor-icon-list-item elementor-repeater-item-3994668 elementor-inline-item\" itemprop=\"about\">\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t\t<svg xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"32\" height=\"32\" viewBox=\"0 0 32 32\" fill=\"none\"><g clip-path=\"url(#clip0_2583_9867)\"><path d=\"M29.4189 1.30371H18.5566C18.1515 1.3037 17.7503 1.38348 17.3761 1.5385C17.0018 1.69352 16.6617 1.92074 16.3752 2.2072L1.75713 16.8253C1.6137 16.9685 1.49991 17.1387 1.42228 17.3259C1.34465 17.5132 1.30469 17.7139 1.30469 17.9166C1.30469 18.1193 1.34465 18.3201 1.42228 18.5073C1.49991 18.6946 1.6137 18.8647 1.75713 19.008L12.9926 30.2434C13.1358 30.3868 13.3059 30.5006 13.4932 30.5783C13.6805 30.6559 13.8812 30.6959 14.0839 30.6959C14.2866 30.6959 14.4874 30.6559 14.6746 30.5783C14.8619 30.5006 15.032 30.3868 15.1753 30.2434L29.7933 15.6253C30.0799 15.3389 30.3072 14.9989 30.4622 14.6246C30.6173 14.2503 30.697 13.8491 30.6968 13.4439V2.58163C30.6968 2.2427 30.5622 1.91766 30.3225 1.678C30.0829 1.43835 29.7578 1.30371 29.4189 1.30371ZM24.9462 8.97121C24.5671 8.97121 24.1965 8.85879 23.8812 8.64816C23.566 8.43753 23.3203 8.13816 23.1752 7.78789C23.0302 7.43763 22.9922 7.05221 23.0662 6.68037C23.1401 6.30853 23.3227 5.96698 23.5908 5.6989C23.8588 5.43082 24.2004 5.24826 24.5722 5.17429C24.9441 5.10033 25.3295 5.13829 25.6798 5.28337C26.03 5.42846 26.3294 5.67415 26.54 5.98938C26.7507 6.30461 26.8631 6.67521 26.8631 7.05434C26.8631 7.30606 26.8135 7.55533 26.7172 7.78789C26.6208 8.02046 26.4796 8.23177 26.3016 8.40977C26.1236 8.58777 25.9123 8.72897 25.6798 8.8253C25.4472 8.92163 25.1979 8.97121 24.9462 8.97121Z\" fill=\"#F9FAFB\"><\/path><path d=\"M29.4189 1.30371H18.5566C18.1515 1.3037 17.7503 1.38348 17.3761 1.5385C17.0018 1.69352 16.6617 1.92074 16.3752 2.2072L1.75713 16.8253C1.6137 16.9685 1.49991 17.1387 1.42228 17.3259C1.34465 17.5132 1.30469 17.7139 1.30469 17.9166C1.30469 18.1193 1.34465 18.3201 1.42228 18.5073C1.49991 18.6946 1.6137 18.8647 1.75713 19.008L7.43874 24.6896L23.6683 8.47155C23.4713 8.29928 23.3118 8.08839 23.1997 7.85195C23.0876 7.61551 23.0253 7.35856 23.0166 7.09704C23.0079 6.83551 23.053 6.57499 23.1491 6.33161C23.2452 6.08824 23.3903 5.86721 23.5754 5.68223C23.7605 5.49724 23.9816 5.35225 24.225 5.25623C24.4684 5.16022 24.729 5.11524 24.9905 5.12407C25.252 5.1329 25.5089 5.19536 25.7453 5.30757C25.9817 5.41979 26.1925 5.57937 26.3647 5.77642L30.3786 1.75993C30.2614 1.61877 30.1148 1.50484 29.949 1.42606C29.7833 1.34727 29.6024 1.30552 29.4189 1.30371Z\" fill=\"#A0ABC0\"><\/path><path d=\"M29.4189 1.30371H18.5566C18.1515 1.3037 17.7503 1.38348 17.3761 1.5385C17.0018 1.69352 16.6617 1.92074 16.3752 2.2072L1.75713 16.8253C1.6137 16.9685 1.49991 17.1387 1.42228 17.3259C1.34465 17.5132 1.30469 17.7139 1.30469 17.9166C1.30469 18.1193 1.34465 18.3201 1.42228 18.5073C1.49991 18.6946 1.6137 18.8647 1.75713 19.008L12.9926 30.2434C13.1358 30.3868 13.3059 30.5006 13.4932 30.5783C13.6805 30.6559 13.8812 30.6959 14.0839 30.6959C14.2866 30.6959 14.4874 30.6559 14.6746 30.5783C14.8619 30.5006 15.032 30.3868 15.1753 30.2434L29.7933 15.6253C30.0799 15.3389 30.3072 14.9989 30.4622 14.6246C30.6173 14.2503 30.697 13.8491 30.6968 13.4439V2.58163C30.6968 2.2427 30.5622 1.91766 30.3225 1.678C30.0829 1.43835 29.7578 1.30371 29.4189 1.30371ZM24.9462 8.97121C24.5671 8.97121 24.1965 8.85879 23.8812 8.64816C23.566 8.43753 23.3203 8.13816 23.1752 7.78789C23.0302 7.43763 22.9922 7.05221 23.0662 6.68037C23.1401 6.30853 23.3227 5.96698 23.5908 5.6989C23.8588 5.43082 24.2004 5.24826 24.5722 5.17429C24.9441 5.10033 25.3295 5.13829 25.6798 5.28337C26.03 5.42846 26.3294 5.67415 26.54 5.98938C26.7507 6.30461 26.8631 6.67521 26.8631 7.05434C26.8631 7.30606 26.8135 7.55533 26.7172 7.78789C26.6208 8.02046 26.4796 8.23177 26.3016 8.40977C26.1236 8.58777 25.9123 8.72897 25.6798 8.8253C25.4472 8.92163 25.1979 8.97121 24.9462 8.97121Z\" stroke=\"#222222\" stroke-width=\"1.33\" stroke-linecap=\"round\" stroke-linejoin=\"round\"><\/path><\/g><defs><clipPath id=\"clip0_2583_9867\"><rect width=\"32\" height=\"32\" fill=\"white\"><\/rect><\/clipPath><\/defs><\/svg>\t\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text elementor-post-info__item elementor-post-info__item--type-terms\">\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-post-info__terms-list\">\n\t\t\t\t<a href=\"https:\/\/www.castfast.com\/en\/category\/case-study\/\" class=\"elementor-post-info__terms-list-item\">Case study<\/a>, <a href=\"https:\/\/www.castfast.com\/en\/category\/knowledge\/\" class=\"elementor-post-info__terms-list-item\">Knowledge<\/a>\t\t\t\t<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-179af2da e-flex e-con-boxed e-con e-parent\" data-id=\"179af2da\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-3d47e120 elementor-widget elementor-widget-theme-post-excerpt\" data-id=\"3d47e120\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"theme-post-excerpt.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\tA critical spare part for a cooling water pump used in a German power plant could no longer be obtained from the original manufacturer. Drawings or even a model for the ultra-complex cast part (guide vane housing, pump built in 1971) were also no longer available. Thanks to the combination of precision measurement and model-free casting (3D sand printing), the pump component could still be manufactured. And next time it will even be possible at the touch of a button.   \t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-db8fdbe e-con-full e-flex e-con e-child\" data-id=\"db8fdbe\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-7d8a39e3 elementor-widget elementor-widget-text-editor\" data-id=\"7d8a39e3\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\tPump specialist GVT takes care of the maintenance of the power plant&#8217;s cooling water pumps. To ensure the long-term operation of older pumps, at least one of the rarely required spare parts is always kept in stock. When the last original spare part for the guide vane housing was used, a new one was needed for the shelf. GVT turned to the CASTFAST team to recast the component as a one-off casting using 3D sand printing technology. The patternless process is often the only economical method for complex one-off parts, but is also worthwhile for simpler cast parts in small series due to its speed and precision.    \n<h3>Old component, modern casting process<\/h3>\nMarcel Tschillaev from CASTFAST, explains:\n<blockquote>\u201cThe pump weighs over 10 tons and measures six meters in length. The guide vane housing is the largest cast part and has a rather complicated inner workings. Fifty years ago, highly complex sand molds with elaborate cores were used to manufacture the original part. Repeating this process today would not be economical for a single spare part. The complexity would be expensive for the customer and would mean a months-long model construction phase. With 3D sand printing, we can print the mold directly without adding complexity.<\/blockquote>\u201d\nThe sheer size of the guide vane housing nevertheless presented the team with challenges. There were two problems to overcome: Firstly, although the 3D sand printer doesn&#8217;t need a wooden model to create the casting mold, it can&#8217;t do without everything. The print file needs 3D data for the component. However, there were not even any drawings available.   \n\n<img decoding=\"async\" class=\"alignnone size-full wp-image-1266\" src=\"https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/03\/02-Form-scaled.jpg\" alt=\"\" width=\"2560\" height=\"2002\">\n\nDenis Germann from GVT explains: \u201cTo reconstruct drawings of the spare part, we work together with the measurement specialists from Sigma 3D. They also measure very large parts on site, using mobile 3D scanners and sophisticated software. This enabled us to send the 3D data directly to the CASTFAST team.\u201d\n<h3>A core with an increased level of difficulty<\/h3>\nThe second problem was the size of the core required to reproduce the internal geometry of the guide vane housing. Cores are normally simply printed in the 3D sand printer. However, this core, with a diameter of over one meter, exceeded the installation space of the sand printers at CASTFAST. It had to be printed externally in an even larger printer, securely packed in sand, shipped and carefully unpacked at the last minute in the foundry and installed in the mold.   \n\nThe casting took place in Mainz in December 2023. The next step was post-processing and coating to make the guide vane housing resistant to salt water. Finally, there was a trip to Bremen, to the special test bench for extra-large pumps. The new pump part is now ready for use and can step in at any time if the last original component currently installed can no longer do the job.   \n\nDenis Germann concludes:\n<blockquote>\u201cHaving to manufacture very old pump parts from scratch using reverse engineering &#8211; that doesn&#8217;t happen very often. We can usually still obtain them from the original manufacturer. If that&#8217;s not possible, the CASTFAST team&#8217;s 3D sand printing now provides us with a method that makes the process a lot easier for us. And the next time we need that specific spare part, we can order it at <a href=\"https:\/\/www.castfast.com\/en\/\">the touch of a button<\/a>.\u201d   <\/blockquote>\n<h3>Profile<\/h3>\nComponent size (raw casting): 1400x1400x1050 mm\nComponent weight: 2500 kg\nMaterial: EN-GJL-250\nProcess: 3D sand printing:\nShape: Quartz sand with furan resin binder\nCore: extra fine quartz sand with furan resin binder\n<h3>Partners involved<\/h3>\n<ul>\n \t<li><a href=\"http:\/\/gvt-vakuum.de\">GVT<\/a> (pump specialist)<\/li>\n \t<li><a href=\"http:\/\/sigma3d.de\/\">Sigma 3D<\/a> (surveying, reverse engineering)<\/li>\n \t<li>CASTFAST<a href=\"https:\/\/www.castfast.com\/en\/?p=5163\">(3D sand printing<\/a>)<\/li>\n \t<li><a href=\"http:\/\/roemheld-moelle.de\/\">R\u00f6mheld &amp; Moelle<\/a> (cast)<\/li>\n<\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-6c395752 elementor-widget elementor-widget-post-navigation\" 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href=\"https:\/\/www.castfast.com\/en\/2025\/08\/13\/poured-quickly-delivered-faster-thats-how-it-works\/\" tabindex=\"-1\" ><div class=\"elementor-post__thumbnail\"><img decoding=\"async\" width=\"300\" height=\"200\" src=\"https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/06\/CX36775-300x200.webp\" class=\"attachment-medium size-medium wp-image-5009 not-transparent\" alt=\"\" srcset=\"https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/06\/CX36775-300x200.webp 300w, https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/06\/CX36775-1024x683.webp 1024w, https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/06\/CX36775-768x512.webp 768w, https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/06\/CX36775-1536x1024.webp 1536w, https:\/\/www.castfast.com\/wp-content\/uploads\/2024\/06\/CX36775-scaled.webp 1920w\" sizes=\"(max-width: 300px) 100vw, 300px\" data-has-transparency=\"false\" data-dominant-color=\"4d4947\" style=\"--dominant-color: #4d4947;\" \/><\/div><\/a>\n\t\t\t\t<div class=\"elementor-post__badge\">Knowledge<\/div>\n\t\t\t\t<div class=\"elementor-post__text\">\n\t\t\t\t<h3 class=\"elementor-post__title\">\n\t\t\t<a href=\"https:\/\/www.castfast.com\/en\/2025\/08\/13\/poured-quickly-delivered-faster-thats-how-it-works\/\" >\n\t\t\t\tPoured quickly, delivered faster &#8211; that&#8217;s how it works!\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-post__meta-data\">\n\t\t\t\t\t<span class=\"elementor-post-date\">\n\t\t\t2025-08-13\t\t<\/span>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t<article class=\"elementor-post elementor-grid-item post-5232 post type-post status-publish format-standard has-post-thumbnail hentry category-knowledge\" role=\"listitem\">\n\t\t\t<div class=\"elementor-post__card\">\n\t\t\t\t<a class=\"elementor-post__thumbnail__link\" href=\"https:\/\/www.castfast.com\/en\/2025\/03\/21\/large-castings-with-castfast-think-bigger-act-faster\/\" tabindex=\"-1\" ><div class=\"elementor-post__thumbnail\"><img loading=\"lazy\" decoding=\"async\" width=\"300\" height=\"199\" src=\"https:\/\/www.castfast.com\/wp-content\/uploads\/2025\/03\/12322_52702_006B-300x199.avif\" class=\"attachment-medium size-medium wp-image-5085 not-transparent\" alt=\"\" srcset=\"https:\/\/www.castfast.com\/wp-content\/uploads\/2025\/03\/12322_52702_006B-300x199.avif 300w, https:\/\/www.castfast.com\/wp-content\/uploads\/2025\/03\/12322_52702_006B-1024x680.avif 1024w, https:\/\/www.castfast.com\/wp-content\/uploads\/2025\/03\/12322_52702_006B-768x510.avif 768w, https:\/\/www.castfast.com\/wp-content\/uploads\/2025\/03\/12322_52702_006B-1536x1020.avif 1536w, https:\/\/www.castfast.com\/wp-content\/uploads\/2025\/03\/12322_52702_006B-2048x1360.avif 2048w\" sizes=\"(max-width: 300px) 100vw, 300px\" data-has-transparency=\"false\" data-dominant-color=\"878180\" style=\"--dominant-color: #878180;\" \/><\/div><\/a>\n\t\t\t\t<div class=\"elementor-post__badge\">Knowledge<\/div>\n\t\t\t\t<div class=\"elementor-post__text\">\n\t\t\t\t<h3 class=\"elementor-post__title\">\n\t\t\t<a href=\"https:\/\/www.castfast.com\/en\/2025\/03\/21\/large-castings-with-castfast-think-bigger-act-faster\/\" >\n\t\t\t\tLarge castings with CASTFAST: Think bigger, act faster!\t\t\t<\/a>\n\t\t<\/h3>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-post__meta-data\">\n\t\t\t\t\t<span class=\"elementor-post-date\">\n\t\t\t2025-03-21\t\t<\/span>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/article>\n\t\t\t\t<\/div>\n\t\t\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>A critical spare part for a cooling water pump used in a German power plant could no longer be obtained from the original manufacturer. Drawings or even a model for the ultra-complex cast part (guide vane housing, pump built in 1971) were also no longer available. Thanks to the combination of precision measurement and model-free casting (3D sand printing), the pump component could still be manufactured. And next time it will even be possible at the touch of a button.   <\/p>\n","protected":false},"author":8,"featured_media":4924,"comment_status":"closed","ping_status":"open","sticky":false,"template":"elementor_header_footer","format":"standard","meta":{"inline_featured_image":false,"footnotes":""},"categories":[52,49],"tags":[],"class_list":["post-5194","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-case-study","category-knowledge"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Spare part for giant pump recast | CASTFAST<\/title>\n<meta name=\"description\" content=\"Thanks to 3D sand printing, a highly complex replacement part for an old industrial pump can be manufactured economically. 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