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Rapid Prototyping / Additive Manufacturing
Rapid Prototyping is the quick and cost-efficient production of workpieces (prototypes, samples, models, tools and finished products) using additive production methods. In contrast to the traditional production processes, such as using milling machines that work the finished part out from blocks of solid materials, in rapid prototyping the workpiece is being built up in layers by specially developed machines.
The initial RP processes were developed in the 1980s. Since then, some new RP processes have been added which, among other things, opened up new application areas. Thus, by utilising rapid prototyping, by now workpieces can be created of plastics and metals in small quantities at series quality. Today, these processes are called additive manufacturing processes.Process
Additive manufacturing is applied at Grunewald for the production of 3D-printed sand molds and cores. Based on 3D product data, the sand molds and cores are designed within our CAD department. Considering our longtime casting experience and available simulation technology, the casting system is designed as a part of the mold construction. This ensures a high level of process reliability, even for higher quantities and recurring products. After finishing the CAD-design, the sand molds and cores can be directly printed with our 3D production printer (ExOne S-Max KHP). Finally the casting is executed with our well-established casting technologies.
Advantages of Additive Manufacturing
Additive manufacturing as a key technology enables new possibilities for the casting process. This results into many advantages for the production of prototypes and low quantities.
Complex Part Geometries:
Additive manufacturing allows the production of complex part geometries, which are not possible or very expensive with convetional production methods. For instance undercuts can be processed and draft angles are not required. Hereby, parts can already be produced at an early stage of the development process to gather a first feedback for the design.
Cost-efficient Production of Prototypes and Low Quantities:
Especially for prototypes and low quantities, additive manufacturing is a very cost-efficient method. Patterns and core boxes are not required, which means much lower investment costs. But also for higher quantities benefits can be generated. Complex areas and cores can be printed directly, so expensive pattern machining and core boxes can be avoided.
Short Lead Times:
Due to the direct manufacturing of sand molds and cores, lead times for patterns and core boxes do not apply and thus first castings can be produced within two weeks. The reduced lead times are a substantial supports for decreasing development cycles.