The 300 L and 40 L/h VOXELJET VX1000S cell deposits a pre-activated layer of sand and, by injecting the binder into the area defined by the CAD, binds the mould layer by layer. Its two heads control the droplet size, flow rate and layer thickness. The printed mould/mould can have very complex 3D geometry, eliminating the physical model and with a design freedom unthinkable in conventional moulding. Manufacturing flexibility enables innovations in additive manufacturing, casting (filling, solidification, shell moulding) and component design.
AM/3D Printing Process
3D Printer unit VOXELJET VX 1000S
Omega 303P Sand mixer system and Omega 303P activator
Parking position for curing and unpacking station
Print heads with flow microinjectors and parametrizable thickness
Rapid 3D Software for the layout adjustment and moulds packaging
Demonstrators and highly complex metallic components combining two processes “near the shape”: additive and casting manufacturing to improve them in terms of design, properties and new functionalities. Combined with another BDIH active, sand moulds and prototypes made with steel, cast iron, or other base material (Ni, Al,…) could be supplied.
To increase the heat transfer, the manufacturing of cores is performed with inner reticular structure, by performing location of integrated metallic inserts of other materials; by application of different coatings which provoke the dissipation
Optimization of additive manufacturing process by means of optimized deposition trajectories, optimized drop size and flow profiles; and coupled to the deposition trajectory to produce “stair step free” sand moulds. By reducing the steps in the mould, the roughness of the manufactured components is reduced.
-New non-conventional filling (helical) and/or feeding systems (parabolic risers, conical helix) with optimized designs made by simulation (Quikcast, Procast, Kassandra) will be tested. -It makes easier the sensorization for thermal monitoring, dynamic, gases, … -Innovation in the layout of mould, partition lines, single moulding, etc.
Design/redesign of highly complex prototypes to be manufactured by casting in 3D printed sand moulds, minimizing subsequent machining operations. The cell allows to perform complex geometries impossible to be manufactured by traditional moulding system: very thin thicknesses, bio-inspired designs, lightened designs, topologic optimization, reticular structures, …
Manufacturing of shell moulds (thin thicknesses). In this way, complex geometries with high solidification rates could be combined. That means, microstructures with better properties and functionalities will be obtained