NAME 3D printing sand moulds cell

DESCRIPTION

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.

FIELDS OF APPLICATION

AM/3D Printing Process

MOST OUTSTANDING EQUIPMENT AND COMPONENTS

  • 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

SERVICES OFFERED BY THE ASSET

Manufacturing of highly complex demonstrators and prototypes

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.

Manufacturing of moulds/cores to facilitate heat transfer

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

Manufacturing of sand moulds/cores with high superficial quality

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.

Optimization of foundry processes in sand moulds

-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.

Redesign of highly complex metallic prototypes

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, …

Shell moulds

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

ENTITY MANAGING THE ASSET

ENTITY MANAGING THE ASSET
FUNDACIÓN AZTERLAN
Contact person:
Gorka Zarrabeitia Trujillo
gzarrabeitia@azterlan.es