ACTech, a leading prototype and casting production specialist has partnered with the 3D printing company, ExOne. ACTech has revolutionised its production processes, by integrating ExOne’s advanced sandcasting system to improve speed and efficiency. The firm said the new machines have also enabled the realization of complex components in record time.
‘The introduction of printed sand cores through collaboration with ExOne exemplifies how modern technologies are reshaping prototype manufacturing,’ ACTech said.
‘This success story highlights the seamless integration of sand printing technology at ACTech and its pivotal role in modern casting production,’ it added.
Challenges: Intricacy and Time limitations
In ACTech’s core business of prototype manufacturing, precision and speed are critical. The castings produced often have intricate geometries and detailed structures to meet the rigorous standards of the automotive, mechanical engineering, and aerospace industries. Traditional manufacturing methods faced difficulties in handling these complexities, especially in mold and core production. To stay competitive, ACTech needed innovative technologies that could accelerate development cycles while maintaining exceptional quality and accuracy.
Solution: ExOne Machines and Sand Printing
The adoption of ExOne machines marked a significant milestone in ACTech’s production. Utilizing advanced sand printing technology, these machines enable the direct 3D printing of sand molds and cores, eliminating the need for conventional manufacturing methods. In operation for nearly a decade, they stand out for their large build platforms and high printing speeds. With build volumes reaching up to 1800 x 1000 x 700 mm, they can produce large-scale sand molds in a single pass, dramatically shortening production cycles.
Additionally, this process facilitates the creation of intricate geometries and undercuts that are often challenging to achieve with traditional techniques.
Results: Higher Precision, Speed, and Flexibility
The adoption of sand printing technology has dramatically accelerated production while improving casting quality. By removing the need for physical models, it reduces both costs and lead times. Additionally, even the most intricate components are manufactured with outstanding surface quality, minimizing the need for extensive post-processing.
Enhancing Efficiency with the Cold Phenol Process (CPP)
The integration of the Cold Phenol Process (CPP) has further increased efficiency, offering several key advantages:
- Reduced Cleaning Effort: The low adhesion tendency of phenolic resin results in smoother sand cores, significantly minimizing mechanical post-processing.
- Eco-Friendly Production: Higher recycling rates of adhered molding materials contribute to a more sustainable and environmentally friendly post-processing workflow.
- Optimized Core Removal: When combined with ACTech’s in-house finishing technologies, the process enhances decoring efficiency, even for the most complex geometries.
By seamlessly integrating printed cores with conventional sand casting, ACTech adapts to individual customer requirements, including larger production volumes. This flexibility provides a crucial competitive edge, especially for time-sensitive projects.
Through its strong partnership with ExOne and its ongoing advancements in manufacturing technologies, ACTech continues to lead the way in prototype and casting production.
About ACTech
ACTech has delivered high-precision metal prototypes to the automotive, mechanical engineering, and aerospace industries. The firm which offers tailored solutions for demanding components, has produced over 240,000 prototypes and a broad range of materials.
By using technologies such as sand printing and metal 3D printing, the company aims to set new standards in quality, speed and innovation.
The firm is headquartered in Freiberg, Germany and was founded in 1995.
