Through its bureau service, Voxeljet produces moulds for casting from CAD data. Through implementing the Generis Sand Process, the user benefits from crucial time and cost savings.
Based on 3D CAD data the moulds are made fully automatically without tools, using the layer building method in the required mould material. The laborious and costly route through the otherwise necessary mould set-up is entirely dispensed with.
"We can reduce the time from entering the CAD data to the delivery of the first mould parts down to three days!" Cast parts are produced in less than two weeks. The complexity of parts is only marginally relevant.
We use moulding material that is generally used in foundries - e.g. silicea and furan resin. We therefore achieve mould and cast properties almost identical to series production. The maximum mould size is currently 1.5 x 0.75 x 0.7m.
Small to medium quantities are the strength of the process; a batch size of one can be also economical and viable. The dispatch of moulds and cores is smooth and reliable.
Services and interfaces
The delivery time for individual items and small series production is 5 days from receipt of order. In return for a small extra charge, delivery times of less than 3 days can be achieved.
The cores are shipped according to urgency by forwarding agent or courier direct to the customer and are immediately ready for casting. You will be amazed at the cost savings resulting from our process as opposed to conventional production.
Technical data
Max. size:
1500 x 750 x 700 mm³
Loss on ignition:
< 2%
Solution:
± 200 µm
Build speed:
12 - 48 mm/h
Layer thickness:
0.2 – 0.4 mm
Accuracy:
0.1% (approx. +/- 0.2 mm in x/y, +/- 0.4 mm in z)
Bending strength:
> 220 N/cm²
Building speed:
12 – 24 mm/h
Used materials
Material
Silica
Description:
GS 14
GS 19
GS 09
Average Grain size (mm):
0.14
0.19
0.09
Application:
moulds and cores for high demand
cores with high gas permeability
moulds with best surface and acceptable gas permeability
Binder content (weight %):
0.9 – 1.2
0.9 – 1.2
0.9 – 1.2
Layer thickness (mm):
0.22 – 0.3
0.3 – 0.35
0.2 – 0.3
Binder:
Furan resin*
* Andalusit and zirconia can also be used
Customer benefit
1. Time advantage
3D CAD is generally used to build the complex cast parts. For the first product sampling a smaller batch of functional prototypes is required, which must feature properties identical to the series production. These parts are usually manufactured by means of sand casting.
With regard to the tools required for this purpose, the model and mould designer requires up to several weeks under the conventional method, depending on complexity. Often after the testing phase, changes are necessary. These require time-intensive reworking of tools, unlike with our shortened process chain. We are able "to print" the required moulds without pattern-making in far less time. The time advantage through to the finished cast part can amount to several weeks.
2. Cost advantage
In addition to time saving, which also represents an economic advantage but is difficult to put an exact figure on, there is a cost saving effect due to the lack of tooling costs compared to conventional production of the corresponding batch size - here referred to as “edge” quantity.
Cost advantage with the Generis Sand Process
Generally the following correlation applies: When the complexity increases, the limit batch value rises. When the component size increases, the edge quantity value drops. The edge quantity value can be up to several hundred parts depending on complexity and component size.
Casting Service 
