Grunewald Foundry: Excellence in low-pressure sand casting and engineering solutions

Grunewald, a family-run business with three production sites in Germany, has built up an outstanding reputation in low-pressure sand casting, toolmaking and mechanical engineering. The company offers design, engineering and manufacturing solutions covering casting, milling, assembly and qualification.

Grunewald’s expertise lies in the low-pressure sand casting of aluminium components such as body structures, chassis and engines. The company is capable of melting and casting various aluminium and iron alloys and offers flexible solutions for a range of applications.

By utilising FEM simulation models, Grunewald can optimise and predict the casting process – including mould filling, solidification, residual stresses, shrinkage and warpage – to ensure precise, high-quality results.

Using two state-of-the-art 3D sand printing machines (ExOne S-Max KHP), Grunewald produces sand moulds and cores quickly and efficiently. In addition, H2O Black Wash is used to achieve optimum surface quality and reduce the use of aluminium silicate.

Grunewald’s expertise extends to the production of large, highly integrated components with wall thicknesses of up to 2 mm, using the low-pressure casting principle. This method ensures a smooth, laminar flow during the mould-filling process and controls shrinkage and pressure, resulting in a repeatable, high-quality casting process.

The company offers a comprehensive all-in-one solution, including heat treatment for non-self-hardening aluminium alloys, precision straightening processes for perfect geometric shapes, and NC machining for post-processing operations such as measurement and qualification.

The state-of-the-art Grunewald plant features advanced technology in the moulding and regeneration department, as well as an energy-efficient air-conditioning system with recirculation and heat recovery. The air purification process ensures that the air discharged from the building is often cleaner than the ambient air.

Furthermore, Grunewald’s thermal sand regeneration process enables 95 per cent of the moulding sand to be reused, thereby reinforcing the company’s commitment to sustainable manufacturing.

Grunewald is certified to the following standards:

• DIN EN ISO 50001
• DIN EN ISO 14001
• DIN EN ISO 9001

Source: Primetals Technologies