The development in the useage of 3D printers to rapidly make new prototype parts has significantly expanded over the last decade. The 3D metallic printer is a very good example of that new way to develop new components.
However, if the engineering team has already identified that the mass production of the parts must be made in a sandcasting process (to have a reduced unit price for higher-level or production), then the 3D metallic printed part is not a realistic representation of the production parts made in sandcasting process.
That is where the 3D sand printing technology can make a real difference as the prototypes parts will be made in a sand mould (just like the production units) but by using a 3D sand printer that avoid the customer to buy a production tooling when the final design of the part is not decided yet. This technology enables the foundry to produce sandcast part with a fairly good dimensional precision.
Moreover, it is also possible to produce samples in a record time (often within 1-2 weeks) which is appreciated by the R&D team working hard to improve or launch new products on the market before their competitors.
This reduced lead time to produce short runs of cast parts with the 3D sand printing technology is also useful for the following cases:
• Old equipment cast component that the original tooling is either lost or damaged;
• Random parts required by certain customers in a rare alloy that doesn’t justify to make a production tooling
Our partner DW Clark located in Massachusetts, USA operates 2 foundries using the 3D sand printing technology:
• Sand casting foundry for parts up to 3000 lbs;
• Centrifugal cast foundry on parts of 70’’ OD and less and 2400 lbs and less
Both foundries can pour a large variety of alloys to meet your requirements:
• All carbon steels;
• All low and high steel alloys;
• All stainless-steel grades (including the duplex ones;
• Grey and ductile irons;
• Special nickel and cobalt base alloys;
• Specific non-ferrous alloys such as bronze, bronze-aluminum, copper, etc.
DW Clark has developed the capability to produce high-end parts for industries such as the nuclear power and shipbuilding ones. Certain parts they cast have to meet very severe radiographic testing level 1.
For more details about what DW Clark can do for your requirements, please contact Metallurgical Resources by phone at (514) 236-5441 or by email at pbelley@metallurgicalresources.com.
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