Expand your business - COLMEXThe ExOne binder jetting technology produces cores and molds made of...
Transcript of Expand your business - COLMEXThe ExOne binder jetting technology produces cores and molds made of...
Expand your business3D Core & Mold Printing
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The future of industrial development is placing high demands on foundries and supply companies.
Where cost management and feasibility of complexity are reaching their limits with conventional methods, 3D printing is at the very start of its virtually limitless potential.
3D Core & Mold Printing
Solutions for complexity and growing customer demands
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Strong growth for the future
The industry’s pressure to innovate is creating constant growth for 3D core and mold production
Solutions for feasibility and cost-effectiveness
International competition in the OEM industry is
creating a new, fast-growing business segment
for the casting industry. Where conventional
manufacturing methods can no longer compete
with the innovation and cost pressure demanded
by rising complexity, the ExOne 3D core and mold
production provides new solutions for innovation,
feasibility and cost-effectiveness.
Creating profitable business areas
As a result of the industry’s ambitious objectives to
constantly improve the performance of cast parts,
foundries are increasingly becoming solution pro-
viders at eye level with the client. The optimization
of wall thicknesses, the improvement in ergo-
nomics and the reduction of individual cast parts
are creating highly profitable business areas. It is
exactly these business areas where the precision
and problem-solving competence of the unique
ExOne technology really make a difference.
Pro
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Imp
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Use
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Be ahead with 3D core & mold printing
› Enhances the value added chain and expands the core business of foundries
› Generates high profitability for prototype manufacturing and series production
› Creates fast and unique solutions especially for high-complexity projects
› Provides a competitive edge and development competencies in the face of
international competitive pressure
› Is a significant part of Industry 4.0
Industry sectors
› Automotive industry
› Construction indutry
› Aerospace
› Engineering
› Pump industry
› Rail industry
› Naval industry
› Defence industry
› Oil & Gas industry
› Wind power industry
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Freedom in Part Geometry
Unbeatable productivity for demanding and complex structures
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ExOne’s technology allows
unique, geometric freedoms
otherwise unaffordable or
impossible in conventional
mold production.
From prototypes to series production in just a few hours
Unique solutions for ultra-complex part geome-
tries and structures are at the very heart of 3D core
and mold printing. Whether for producing molds
previously impossible or for infinitely variable
core geometries. Now everything can be done
simultaneously – even in a single print. Where
prototype production used to take many weeks,
ExOne’s technology delivers in just a few days or
even hours.
High flexibility and responsiveness for a tremendous range of variants
Designed in a CAD today and delivered as a
finished prototype tomorrow. 3D core and mold
printing by ExOne ensures absolute flexibility
in the production of complex molds. There are
no limits to the rising industry demand for variant
versatility and individual customer solutions, or in
the production flexibility of international locations.
Gain in quality and production safety
ExOne’s 3D core and mold printing technology is
a gain in quality and production safety. Flexible
prototyping produces fast, high-quality results –
especially when testing sophisticated molds and
improving tolerances. And the surface quality is
likewise impressive. Getting rid of snap tabs and
seams translates into a huge quality improvement
of the end product.
Maximum output with maximum complexity
› Efficient results even with highly complex and delicate designs
› Entirely novel and previously unheard-of geometries and structures from a single piece
› Improvement of tolerances and surface quality
› Production flexibility even in the face of rising demands for variant versatility
› Responsiveness in meeting the requirements of international conditions regarding location
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Die ExOne-Technologie ist in der
Herstellung von komplexen For-
men ökonomisch und profitabel.
3D Kern- & Formdruck senkt
den Zeit- und Kostenaufwand
bei gleichzeitig höheren Mar-
gen.
Convincing Cost-Effectiveness
Profitability and the proof that less is truly more
High profit for high complexity
In the production of complex casting molds, the
ExOne technology is “best in class” with respect
to profitability and cost-effectiveness – and will
continue to do so in the future. Spending less time
and money on creating a sophisticated casting
mold otherwise impossible by existing processes,
results in an improved bottom line. At every step of
the value added chain.
Incremental service and higher price acceptance
The ExOne printing system makes you the perfect
solution provider for any client. Cores and molds
of high complexity or innovative standards have a
considerably higher value for your customers than
standard productions. This allows you to offer an
additional service while benefiting from higher
margins.
Decreases time and development costs
The ExOne technology has put an end to long
development times and high costs of prototype
manufacturing and serial production. Serial pro-
duction is highly efficient and economical – espe-
cially for highly complex products. At the touch of
a button, with the parameters coming straight from
the CAD, 3D core and mold printers provide fast
results in just a few hours or days instead of weeks
or months.
Reduction in operating costs
The list is long: savings of energy costs and person-
nel costs, reduction in procurement processes and
storage, minimal multi-piece molds, no assembly
of individual parts, no complicated tool changes
and no manufacturing costs for tools, no support
structures and structural panels – and many more
potential savings speak for ExOne 3D printing. In
addition, 3D production also permits innovative
mold packages enabling different casting orienta-
tions without any limits on filling. Including more
efficient riser and feeder locations can help cut
down on work processes and save valuable raw
materials.
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The ExOne technology is
economical and profitable
when producing complex molds.
3D core & mold printing reduces
time and cost while increasing
margins.
More profit and less costs
› Complexity increases the industry’s acceptance of higher prices
› Considerable time saving due to delivery in a few hours / days
instead of weeks / months (with the parameters coming directly from the CAD)
› Outstanding cost savings in development and prototype production
› Continuous savings in operating costs
› Optimization of consumables and raw materials
(also thanks to internal bionic structures, such as hatching)
3D core and mold printing by ExOne impresses twofold: for
cost-effectiveness
in prototyping
and for series
production of
highly complex
molds
COMPLEXITY
CO
STS
PER
PA
RT
Traditional Manufacturing
3D Core & Mold Printing
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Binder Jetting Technology
Precision and reliability thanks to unique printing technology
Indirect printing of ultra-complex part geometries
The patented ExOne binder jetting technology is a
globally unique procedure, developed especially
for rapid printing of ultra-complex part geome-
tries. The layer by layer process guarantees max-
imum precision while immediately turning digital
models into reality.
Building cores and molds layer by layer
The innovative print head and recoater (sand
distribution) facilitate high printing speeds.
Alternating layers of molding material (sand lay-
ers) and binder materials (industrial binders) are
applied in this process. The process is continually
repeated until the cores and molds are complete.
This way, almost any geometric property can be
realized which would otherwise be impossible with
conventional production processes.
Start layer:First the recoater applies 4-8 sand layers on the bottom of the jobbox.
Printing:The print head is selec-tively applying a first layer of binder on the activated sand.
New layer:The print platform in the jobbox is lowered by one layer height.
Recoating:The recoater is applying a new layer of activated sand.
Repeating: Steps 2-4 are repeated until the core/mold is finished.
Finishing:The unbound sand is removed from the jobbox and the sand mold/core is ready for use.
Various applications
› Prototypes & Product Development
› Serial Production of Complex Parts
› Exclusive Productions
› Reproduction of no longer available parts (Reverse Engineering)
› Parts consisting of Composite Materials (Wash-out Tooling)
The ExOne binder jetting
technology produces cores
and molds made of molding
materials and special binders
in an indirect printing process
– directly from the CAD data.
Flexible, precise and in the
shortest possible time.
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Solutions
for individual challenges
Cast products come with different performance and profitability requirements in every sector of the industry.
ExOne focuses strictly on your objectives.
From an understanding the complexi-
ty requirements and envisaged casting
materials to an understanding of long-
term, economic objectives all the way to
complete integration in existing produc-
tion processes and a new future for your
company.
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Consultation & Commissioning
Experts for change management and technology integration
Integrating a new future for your company
The introduction of 3D core and mold printing technology means change and development in the
corporate organization. The ExOne experts support you in three phases during the first step: the planning
of your change management process, the development of short-term and long-term future scenarios,
and purchasing planning as a whole.
Expertise for optimum production conditions
Our experts understand the individual require-
ments in the different industries and will work with
you to analyze all the requirements demanded of
the casting products you are planning to produce.
Allow us to assist you with your competence infea-
sibility analysis and efficiency increases to make
you ready for the the cutting edge in research and
development
From planning to comissioning
We ensure flawless preparation for technology
integration from the very beginning.
The ExOne experts will accompany you during the
entire implementation, from the planning to the
start-up, and will hand over the finished production
process as soon as your employees are trained
and qualified.
The ExOne experts will accompany the entire integration process
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joint anal-ysis of your operation and your economic objectives
Definition of target products and casting materials
Prototype cores and molds from the ExOne Adoption Center
Optimization of cost- effectiveness with external service providers
Integration of your own ExOne 3D core and mold printing production
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Binders & Molding Materials
Combined solutions for any casting requirement
FURANCold Hardening Binder System
CHP Cold Hardening Phenol
Cold Hardening Binder SystemHHP Hot Hardening Phenol
Hot Hardening Binder SystemSILICATEInorganic Binder System
Casting Material Casting Material Casting Material Casting Material
Steel, Iron, Non-ferrous Metal, Aluminum Steel, Iron, Non-ferrous Metal, Aluminum, Bronze Steel, Iron, Non-ferrous Metal, Aluminum, Bronze Non-ferrous Metal, Aluminum
Characteristics* Characteristics* Characteristics* Characteristics*
Hot strength:
Filigree character:
Strength/Loadability:
Finishing:
5 – 10 **
5 – 6
7 – 8
1 – 2
Hot strength:
Filigree character:
Strength/Loadability:
Finishing:
7 – 10
9 – 10
7 – 8
9 – 10
Hot strength:
Filigree character:
Strength/Loadability:
Finishing:
9 – 10
10
10
9 – 10
Hot strength:
Filigree character:
Strength/Loadability:
Finishing:
3 – 4
9 – 10
6 – 7
9 – 10
Molding Material Molding Material Molding Material Molding Material
Silica Sand / Synthetical Sand Silica Sand / Synthetical Sand Synthetical Sand Silica Sand / Synthetical Sand
Additives Additives Additives Additives
Magnesium Inhibitor / Iron Oxyde None None None
Thermal Postprocessing Thermal Postprocessing Thermal Postprocessing Thermal Postprocessing
None Optional Necessary Necessary
* Range 1-10: 10 corresponds to the best suitability.
** With Additive
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S-Print3D Core & Mold Printing System
All-rounder for prototypes and small series
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Output
120 units / jobbox
7-12 production time (h)*
Binder Systems
Furan | Silicate | CHP | HHP
Characteristics
Use: stand-alone solution
External dimensions (m): 2.54L × 3.27B × 2.86H
Build volume (l): 160
Build dimensions (mm): 800 × 500 × 400
Possible layer heights (mm): 0.24 – 0.38
Layer time (sec.): 20 – 25
* Depending on sand binder
Control cabinet
Jobbox• optional external roller conveyor• optional additional jobbox
Twin source sand mixer filled with vacuum or screw conveyor
Operating panelLoading/unloading station
The S-Print combines a compact structure with an extremely versatile range of applications. By giving you
absolute flexibility in selecting any binder system available at ExOne, S-Print is your perfect solution for
virtually all casting materials. Making it the right choice for prototypes and small series.
As with all ExOne 3D core and mold printers, cores and molds can be created from CAD data quickly and
without the need for tools.
150 × 150 × 50 mm
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S-Max3D Core & Mold Printing System
Productivity for all cold hardening binder systems
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Twin source sand mixer filled with vacuum or screw conveyor
Jobbox• for loading & unloading procedures• on motorized roller conveyor• optional second jobbox
Control cabinet
Operating panel
Fluid connections
Output
1008 units / jobbox
16-23 production time (h)*
Binder Systems
Furan | CHP
Characteristics
Use: stand-alone solution
External dimensions (m): 10.40L × 3.52B × 2.86H **
Build volume (l): 1260
Build dimensions (mm): 1800 × 1000 × 700
Possible layer heights (mm): 0.26 – 0.38
Layer time (sec.): 30 – 35
The S-Max offers a robust and reliable solution for all cold hardening binder systems. It is suitable for
almost all casting materials. Large and complex cores and molds can be realized even more quickly and
reliably. With the larger construction platform and double jobbox, the S-Max produces any prototype
requirement and whole series with efficiency and performance.
150 × 150 × 50 mm
* Depending on sand binder
** With 2 Jobboxes
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S-Max+3D Core & Mold Printing System
Specialist for high flexibility for compounds
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Output
864 units / jobbox
17-23 production time (h)*
Binder Systems
HHP | Silicate
Characteristics
Use: system (incl. microwave)
External dimensions (m): 3.86L × 3.51B × 3.47H
Build volume (l): 1080
Build dimensions (mm): 1800 × 1000 × 600
Possible layer heights (mm): 0.24 – 0.38
Layer time (sec.): 35 – 40
The S-Max+ is perfect for series and prototype production of inorganic cores and molds with a high
degree of complexity. Equipped with HHP, its 3D prints are perfect for high-temperature casting. With its
special feature for inorganic materials, it provides particularly high-quality printing results thanks to its
reduced gas emissions. Its modular concept offers a high degree of flexibility for countless variations in
the facility network and Industry 4.0.
150 × 150 × 50 mm
Twin source sand mixer filled with vacuum or screw conveyor
Operating panel
Pedestal
Jobbox
* Depending on sand binderTurntable
Microwave
Roller conveyor
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3D Core & Mold Printing Systems
Technical characteristics comparison
S-Print S-Max S-Max+
Binder Systems
Furan | Silicate | CHP | HHP Furan | CHP Furan | HHP
Characteristics
Use: stand-alone solution stand-alone solution system (incl. microwave)
External dimensions (m): 2.54L × 3.27B × 2.86H 10.40L × 3.52B × 2.86H * 3.86L × 3.51B × 3.47H
Build volume (l): 160 1260 1080
Build size (mm): 800L × 500B × 400H 1800L × 1000B × 700H 1800L × 1000B × 600H mm
Possible layer heights (mm): 0.24 – 0.38 0.26 – 0.38 0.24 – 0.38
Layer time (sec.): 20 – 25 30 – 35 35 – 40
* With 2 jobboxes
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Service
Individual and rapid full service for high productivity and qualityExOne Adoption Center for test productions
The EAC (ExOne Adoption Center) is the first stop
for the introduction of 3D technology into your
company, and for the integration of the system
into existing processes. EAC allows you and our
specialists to print all component geometries for
the planned cores and molds, and to test them in
detail. Depending on the required complexity and
the casting materials used, all binder types and
molding substances can be used.
ExOne Academy for professional team training
Practical knowledge, compact and directly from
the experts: The Academy Training equips your
team for dealing professionally with ExOne 3D
technology – directly and with easy-to-understand
information. Our experts will guide your employ-
ees through a condensed training programme with
the aim of practicable application and rapid imple-
mentation of production objectives. The training
programme offers tried-and-tested learning
methods and modern learning media,
so that your team can master the technology
as easily as possible.
After-sales service and quality assurance
Installation and commissioning
Our service technicians will rapidly integrate and
implement the ExOne 3D printer. Professional
assembly and installation are based on almost 20
years of manufacturing experience. Consideration
of safety aspects plays a central role here.
Call-out
If you need a service technician on-site, you can
be sure that we’re standing by to provide service.
Around the clock if needs be. A concept coordi-
nated to you contains individual reaction times,
ensuring your system availability – from workday
support to 24-hour service.
Telephone support
Do you need a hotline to us? As part of our individ-
ual service agreements, you will receive telephone
support. Through our in-house helpdesk, you
will access our experts, who can provide you with
guidance over the phone around the clock.
Maintenance
Our active maintenance management guarantees
you get a high production quality. Maintenance is
carried out according to our test record specifi-
cations. With regular maintenance, any wear and
tear can be recognised in advance, documented
and immediately rectified as required.
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Global Company
Rely on stability and international competence –with the market leader in 3D indirect printing
ExOne and the unique binder jetting technology
are world leaders in the field of industrial, additive
production procedures. Since 1999, the one-time
start-up in the manufacturing of 3D core and mold
prints has developed from a handful of engineers
into a global technology developer with service
and support networks in Germany, the USA and
Japan.
As a market-listed technology company and
future-focused innovator, ExOne is the perfect
partner for any industrial manufacturer with its
international sites. The company supplies leading
customers from the automobile sector, pump
manufacturing, aerospace industry, the energy
sector and plant construction.
Success story from the idea to the market leader
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3130
USA Mid-West
ExOne 2341 Alger DriveTroy, MI 48083 USA
Phone: +1 248 740 1580
USA Mid-Atlantic
ExOne 127 Industry BoulevardNorth Huntingdon, PA 15642 USAPhone: +1 877 773 9663Phone: +1 724 863 9663
USA North
ExOne North America Research Facility66850 Executive DriveSt. Clairsville, OH 43950USA
Phone: +1 740 695 0397
Germany
ExOne GmbHDaimlerstraße 2286368 GersthofenGermany
Phone: +49 821 65063-0
Japan
ExOne KK Japan161-5 HaneoOdawara-shi, KanagawaJapan 256-0804
Phone: +81 465 44 1303
ExOne EuropeExOne America ExOne Asia
Contact
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Comple ity is simple.
ExOne GmbH
Daimlerstraße 22
86368 Gersthofen
Germany
Phone: +49 821 65063-0
Fax.: +49 821 65063-11
E-Mail: [email protected] www.exone.com 09
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