3D Printed Sand Mold Package for Casting Aluminum Bionic Frame

Grunewald manufactures cast aluminum frames using printed sand molds via binder jetting for SPALECK Oberflächentechnik to replace a welded steel component. 

Grunewald is a family-owned German foundry with a rich history dating back to 1963. Grunewald is renowned for its expertise in low-pressure sand casting, particularly for aluminum components used in automotive applications. The company also has extensive experience in tool making and machine building. Grunewald uses two S-Max sand 3D printers from ExOne to rapidly produce sand molds and cores for both domestic and international clients. 

One of Grunewald’s customers in Germany, SPALECK Oberflächentechnik, specializes in manufacturing surface finishing machines and systems, as well as developing custom surface finishing processes. Before SPALECK Oberflächentechnik discovered Grunewald’s sand 3D printing capabilities, a steel component in one of its surface finishing machines was welded together from many individual struts. 

The company’s surface finishing technology includes several processing systems. One of them is the PPL300 high-frequency system, the latest type of surface finishing process with minimal edge rounding and maximum surface removal originally developed for post-processing of additively manufactured parts. During the surface finishing process, the printed parts and the machine’s connected frame have to be agitated at a high frequency. To perform this high-frequency movement and withstand the generated forces, it is crucial to utilize a lightweight yet strong vibration frame.  

Download the case study to discover how Grunewald solved the limitation of welded steel component with sand 3D printing.

“The printing process is fast and precise, making it an ideal method for prototypes and complex cores” 

Harald Dieckhues, Foundry Manager, Grunewald

“The cast frame successfully replaced the welded part and it was even possible to save approximately 60 kg in weight.” 

David Huls, Sales Engineer, SPALECK Oberflächentechnik

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The above image is courtesy of Lena Demirci, the head of marketing at SPALECK Oberflächentechnik.