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[ExOne Case Study] German Automaker

30/06/21

Achieve Faster Castings with Lower Costs

Premier auto manufacturer saved over 50% in costs and gained flexibility for casting design changes.

  • Customer Challenge : Automotive manufacturer needed a way to quickly and economically produce complex prototypes.
  • The Solution : Printed sand parts to form a complete package for creating castings.

ExOne Sand Printing Method

  • Production Time : 4 hours
  • Cost per Part : $2,017

Traditional Method

  • Patterns and tools for sand core forming, lost foam model parts.
  • Cost per Lot: $20,173-26,897

Specifications

  • Part : Formula 1 Transmission Housing
  • Batch Size : 5 pieces
  • Material Cast : Aluminum alloy 356
  • Material Printed : Silica sand with furan binder system
  • Printed Volume : 200 L for complete mold package

ExOne Competitive Advantage

Additive manufacturing o ers shorter lead times, accommodates changes in design rapidly and enables product design improvements at a reduced cost.

Conclusion

ExOne’s digital printing process o ered significant time and cost advantages over both conventional and other additive technologies for castings.

CAD Renderings

ExOne - German Automaker

About ExOne

ExOne digital part materialization uses three-dimensional printing to create complex molds and cores directly from CAD data for a variety of industries, with accuracies of ± 0.011 in. or ± 0.3mm. The ExOne process achieves geometric complexity and scale unmatched using conventional casting techniques. The process produces accurate, uniform cores and molds rapidly, significantly reducing lead times.

ExOne operates facilities across the Americas, Europe and Asia.

  • Article from our partner ExOne

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