ACTech revolutionises production with 3D printing through its partnership with ExOne

ACTech, a leading specialist in the manufacture of prototypes and castings, has entered into a partnership with the 3D printing company ExOne. ACTech has revolutionised its production processes by integrating ExOne’s advanced sand printing system to improve speed and efficiency. According to the company, the new machines also enable the production of complex components in record time.

“The introduction of printed sand cores through the collaboration with ExOne is an example of how modern technologies are reshaping prototyping,” says ACTech.

“This success story highlights the seamless integration of sand printing technology at ACTech and its central role in modern casting production,” the statement continues.

Challenges: Complexity and time pressure

In ACTech’s core business – prototype manufacturing – precision and speed are crucial. The castings produced often feature complex geometries and detailed structures to meet the stringent standards of the automotive, mechanical engineering and aerospace industries. Conventional manufacturing methods struggled to cope with this complexity, particularly in mould and core production. To remain competitive, ACTech needed innovative technologies that could accelerate development cycles whilst ensuring exceptional quality and accuracy.

Solution: ExOne machines and sand printing

The introduction of the ExOne machines marked a significant milestone in ACTech’s production. These machines utilise advanced sand printing technology and enable the direct 3D printing of sand moulds and cores, thereby eliminating the need for conventional manufacturing methods. They have been in operation for almost a decade and are characterised by their large build platforms and high printing speeds. With a build volume of up to 1800 x 1000 x 700 mm, they can produce large sand moulds in a single pass, thereby drastically shortening production cycles.
Furthermore, this process enables the production of complex geometries and undercuts that are often difficult to achieve using conventional techniques.

Results: Greater precision, speed and flexibility
The introduction of sand printing technology has drastically accelerated production whilst simultaneously improving casting quality. As physical models are no longer required, both costs and lead times are reduced. Furthermore, even the most complex components are produced with excellent surface quality, minimising the need for extensive post-processing.

Increased efficiency with the cold phenol process (CPP)
The integration of the cold phenol process (CPP) has further increased efficiency and offers several key advantages:

• Reduced cleaning effort: The low adhesion tendency of the phenolic resin results in smoother sand cores and significantly minimises the need for mechanical post-processing.
  
  
• Environmentally friendly production: Higher recycling rates of adhering moulding materials contribute to a more sustainable and environmentally friendly post-processing procedure.
  
  
• Optimised core removal: In combination with ACTech’s in-house post-processing technologies, the process enhances the efficiency of core removal, even for the most complex geometries.

Through the seamless integration of printed cores with conventional sand casting, ACTech adapts to individual customer requirements, even for larger production runs. This flexibility is a decisive competitive advantage, particularly for time-critical projects.

Through its close partnership with ExOne and the continuous development of manufacturing technologies, ACTech remains a leader in prototype and casting production.

About ACTech
ACTech supplies high-precision metal prototypes for the automotive, mechanical engineering and aerospace industries. The company, which offers bespoke solutions for sophisticated components, has produced over 240,000 prototypes using a wide range of materials.
By utilising technologies such as sand casting and 3D metal printing, the company aims to set new standards in terms of quality, speed and innovation.

The company is headquartered in Freiberg, Germany, and was founded in 1995.