Sand 3D Printing Success Stories

Dundee Castings, a Tier 2 supplier of premium automotive seating molds to most of the world’s leading automakers users two S-Max Pro binder jetting systems to print complexity directly into the part, improving consistency and quality.  

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BMW uses binder jetting for the automatic, large-scale production of cores to cast cylinder heads for its high-efficiency, straight-six turbo engines. Layer-by-layer production allows complex passages that optimize cooling to be incorporated.

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One of the largest producers of critical cast-iron components in the U.S. recognized that advanced processes like binder jet 3D printing enabled component weight reductions and faster response times that are key to future growth.  

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3D printing on the S-Max enabled Kore Mart to create complex geometries repeatably and in large volumes. Eliminating hard tooling by printing directly from a CAD design reduces production setup times compared to traditional processes.

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The ExOne S-Max enables GF Casting Solutions Leipzig GmbH to consolidate 12 shot cores into one printed core. In addition to improving the core quality, time-intensive and laborious steps are eliminated.

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In 2013 Hoosier Pattern purchased its first ExOne S-Max, making it the first pattern shop in North America to own and operate a sand 3D printer in-house. Today, Hoosier operates three S-Max and one S-Max Pro binder jetting systems.   

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Humtown Products, a third-generation family-owned business, has transformed its outlook with ExOne sand 3D printers that open new business opportunities, such as complex, consolidated cores that require no assembly.

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Xylem, the world-leading water technology company, simplifies production of impellers with ExOne binder jet 3D printing. Impellers with 3D printed cores improve quality while decreasing production costs around 30%.

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Swiss iron foundry Eisengiesserei Mezger expanded its services with the S-Max Pro, semi-automated desanding station, and remote monitoring app from ExOne, allowing them to grow while operating with less labor.

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