Foundry sand 3D printing on an ExOne S-Max Pro

Sand 3D Printing Success Stories

Foundries are using ExOne binder jet technology to dramatically cut lead times, eliminate scrap, and reduce assembly labor needs while casting complex designs with a digital workflow

3D printed molds and cores are the future of metalcasting, allowing foundries to pour increasingly complex geometries or design organic rigging to improve pour quality - all with lead times measured in days, not weeks. Hear from our customers around the world how they successfully implemented sand binder jetting from ExOne to transform their businesses, 

The flexibility of binder jetting allows Liberty Pattern to provide top-quality services for a wide range of customers and applications. A 20+ part core assembly was reduced to a single complex 3D print.  

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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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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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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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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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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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Bring a Sand 3D Printer In-House

ExOne binder jetting can help foundries reduce delivery times and labor requirements. Learn more about the cost of binder jet 3D printing. 


OneCast Design & Engineering  

Our experts pair virtual design and casting simulation with 3D printed mold and core packages for done-in-one pour complex casting development.


Find 3D Printing Services 

Looking for a provider of premium sand molds and cores for your complex or quick-turn metalcasting project? Our network of 3D printer owners can help.



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