Printed Sand Core for a Closed Impeller
The photograph shows a shaped sand core seated within the surrounding printed mold section.
Additive Manufacturing Service
3D Sand Printing for Industrial Metal Casting
Patternless production of sand molds and complex cores from verified CAD data—integrated with casting simulation, metal casting and inspection.
We print the sand molds and cores—not the final metal component. The printed mold is subsequently used in the metal casting process.
- Industrial binder-jet sand printing
- ExOne S-Max system
- Patternless molds and complex cores
- Integrated engineering-to-casting workflow
- Thailand-based engineering and production
When 3D Sand Printing Becomes the Practical Casting Route
3D sand printing is not automatically cheaper or faster than a conventional route. The appropriate production route depends on geometry, quantity, material, tolerance, inspection requirements and schedule.
No Original Pattern Available
For obsolete or replacement components where the original tooling is missing, damaged, or no longer available.
Low-Volume or One-Off Production
For projects where conventional pattern tooling would add disproportionate cost or lead time relative to the quantity required.
Complex Internal Geometry
For components requiring complex cores, internal passages, undercuts, or geometries that are difficult to produce conventionally.
Urgent Engineering Requirements
For projects where the customer needs to shorten the mold-and-core preparation stage of the casting programme.
How an Additive Manufacturing Casting Project Can Start
A project may begin from complete engineering data or from the component itself. The starting point determines how much reconstruction work is required before mold and core production.
Projects without usable CAD data: Reverse Engineering- 2D engineering drawings
- Existing CAD data
- 3D scan data
- A worn or damaged physical component
- An existing pattern or core box requiring redesign
- Performance or dimensional requirements
From Project Data to Verified Casting
The exact workflow and inspection scope are defined according to the component, alloy, quantity, condition of the available data and customer requirements. Not every project uses every stage.
- 01
Requirement Review
- Input
- Drawing, CAD, scan data, sample component, quantity, alloy and delivery requirement.
- Activity
- Project feasibility and manufacturing-route review.
- Output
- Proposed engineering and production route.
- 02
Geometry Preparation
- Input
- Available or reconstructed geometry and material specification.
- Activity
- CAD verification, casting allowances, machining allowances, parting strategy and core development.
- Output
- Casting-ready geometry.
Prepared mold and core data arranged for the printing build. - 03
Casting Simulation
- Input
- Casting-ready geometry, proposed gating and feeding layout.
- Activity
- Evaluation of filling, solidification, gating and feeding strategy where required for the project.
- Output
- Reviewed casting-process proposal.
Mold-filling review carried out before mold and core production, where applicable. - 04
Mold and Core Printing
- Input
- Approved mold and core data.
- Activity
- Print data preparation, component orientation and production of binder-jetted silica-sand molds and cores.
- Output
- Casting-ready mold-and-core package.
Printed sand mold and core package assembled for casting. - 05
Metal Casting
- Input
- Assembled mold-and-core package and specified alloy.
- Activity
- Mold assembly, melting, pouring and controlled production.
- Output
- Raw casting.
Pouring into the assembled mold package during coordinated foundry production. - 06
Finishing and Inspection
- Input
- Raw casting and agreed inspection scope.
- Activity
- Cleaning, finishing, machining coordination and inspection according to project requirements.
- Output
- Inspected component and applicable documentation.
Inspection activities are defined according to the agreed project scope.
Industrial 3D Sand Printing Capability
| Printing system | ExOne S-Max® |
|---|---|
| Printing process | Industrial sand binder jetting |
| Build volume | 1,260 litres |
| Build dimensions | 1,800 × 1,000 × 700 mm |
| Layer height | 0.2–0.5 mm, depending on material and process settings |
| Dimensional accuracy | ±0.5 mm on the printed sand geometry, depending on part size and geometry |
| Sand and binder system | Silica sand with furan binder |
| Mold and core applications | Sand molds, complex cores, internal flow passages and one-off or low-volume mold packages |
| Project data formats commonly received | STEP, STP, STL, DWG, DXF and PDF drawings; scan data or a physical component where no CAD exists |
| Connected casting processes | Casting simulation, coordinated metal casting, machining coordination and inspection |
Accuracy values refer to the printed sand mold or core. Final casting tolerances also depend on alloy shrinkage, mold design, pouring conditions, heat treatment, finishing and machining requirements. Lead times are project-dependent and confirmed per enquiry; these values are not universal guarantees.
Explore Sand Binder Jetting Technology
Manufacturer Reference
Long-Term S-Max Experience
In its LinkedIn feature, ExOne described more than 15 years of S-Max use at Speed 3D Mold and noted that the system remained in production at the time of the post.
View the ExOne FeatureEngineering Checks Before Mold and Core Production
Receiving a CAD file does not automatically mean the geometry is ready for casting.
A printable file is not necessarily a casting-ready design. The geometry must be reviewed in relation to the alloy, filling behaviour, solidification, mold assembly, finishing and inspection requirements.
- Geometry and casting feasibility
- Wall thickness and section transitions
- Shrinkage and machining allowances
- Core design and core positioning
- Parting and mold-assembly strategy
- Gating and feeding concept
- Print orientation and handling considerations
- Inspection and documentation requirements
Where 3D Sand Printing Creates Engineering Value
Documented Mold and Core Examples
The photographs below show molds, cores and mold assemblies produced within Speed3D Mold’s documented manufacturing workflow.
Printed Sand Core for a Steel Pump Bowl
The photograph shows the printed central core and lower mold sections used in the documented steel pump bowl project.
Printed Sand Mold for an Impeller
The photograph shows a sectioned printed sand mold with a circular impeller cavity and locating features.
Where This Workflow Can Be Applied
Project suitability depends on geometry, quantity, alloy, available data, inspection requirements and delivery schedule.
Complex Mold and Core Geometry
Printed sand may support molds and cores that are difficult to produce using conventional tooling.
Replacement Components Without Existing Tooling
Projects may begin from drawings, CAD data, scan data or an existing component, subject to engineering review.
One-Off and Low-Volume Castings
Patternless production may avoid dedicated tooling where the required quantity does not justify conventional pattern equipment.
New Casting Development
Printed molds and cores can support design iteration before the manufacturing route is finalized.
Urgent Mold-and-Core Requirements
Digital mold and core production may shorten the tooling preparation stage, depending on project complexity and production readiness.
Hybrid Production Routes
Printed cores may be combined with conventional molds when that route is more practical for the component.
Documented Project Evidence
Documented Application: Complex Impeller Mold-and-Core Production
Challenge
Four large double-suction impellers were required as replacements, with the customer needing delivery within six weeks. The enclosed double-suction passages would conventionally require dedicated pattern and core equipment.
Engineering and manufacturing route
Casting design and rigging development, casting simulation, preparation of mold and core data, sand 3D printing of the mold-and-core packages, casting and machining.
Verified result
| Scope | Reported time |
|---|---|
| Mold-and-core productionReported printing timeline for the four mold-and-core packages. | Seven days |
| Casting deliverySeparately reported by ExOne as a further period after mold production. | Seven days |
| MachiningReported subsequent machining period. | A further seven days |
The reported seven-day period covers production of the four mold-and-core packages. Casting and machining were reported as further separate periods, so the complete finished components were not delivered within seven days.
- Component
- Double-suction impeller
- Material
- Lead-tin bronze
- Quantity
- Four castings
- Diameter
- 620 mm
- Part weight
- 250 kg each
- Mold package
- 900 mm diameter × 700 mm height
- Print volume
- 650 litres
- Customer requirement
- Replacement within six weeks
- Source
- ExOne case study
From Printed Sand to Metal Component
Mold and core production is connected to actual foundry production rather than supplied as a stand-alone printing service. The printed package is assembled, poured and finished within a coordinated casting programme.
Not every alloy is suitable for every geometry or service condition. Material selection is reviewed against the component, application and inspection requirements for each project.
Aluminium bronze and nickel aluminium bronze
C95400, C95500 and C95800 grades used for seawater pumps, propellers and shafts.
Tin bronze and other copper-based alloys
C90500 tin bronze, leaded red brass C83600 and related copper alloys.
Cast iron and ductile iron
Gray cast iron and ductile iron grades such as ASTM A48, FCD 450 and ASTM A536.
Stainless steel casting alloys
Austenitic grades ASTM A351 CF8 and CF8M, and martensitic ASTM A743 CA6NM.
Inspection Defined Around the Project Requirement
Inspection methods, acceptance criteria and documentation scope must be agreed before production.
Dimensional inspection
Measurement of agreed dimensions and interfaces against the project requirement.
3D scan comparison
Comparison of scan data against the reference geometry where this is part of the agreed scope.
Material verification
Chemical composition verification for the specified alloy, where required by the project.
Visual inspection
Surface and general condition review of the casting after finishing.
Machining inspection
Verification of machined features where machining is coordinated as part of the scope.
Project-specific testing or documentation
Additional testing or records may be applied where agreed before production.
Plan the Right Manufacturing Route
Share the project information currently available. Speed3D Mold will review the component, production requirement and technical constraints to determine whether 3D sand printing, conventional tooling or a hybrid manufacturing route is more appropriate.
Project Information→Engineering Review→Recommended Manufacturing Route
What You Can Share
Available Project Information
Partial information is enough to begin. Missing details can be identified during the engineering review.
- Drawing, CAD file, scan data or physical sample
- Component dimensions and approximate weight
- Required alloy or service environment
- Required quantity
- Machining requirements
- Inspection or certification requirements
- Target delivery date
- Photographs of the existing component
- Known wear, damage or performance problem
What We Evaluate
Engineering and Production Factors
The manufacturing route is selected according to the complete project requirement—not by the printing process alone.
- Geometry and casting feasibility
- Mold, core and assembly strategy
- Component size and handling requirements
- Material and process compatibility
- Quantity and expected repeat demand
- Surface finish and dimensional requirements
- Tooling availability
- Inspection and documentation scope
- Required schedule and production readiness
The Outcome of the Review
Based on the available project information, Speed3D Mold may recommend printed sand molds and cores, conventional tooling, a hybrid route, or further engineering work before production. The appropriate route depends on the component and project requirements.
3D Sand PrintingConventional ToolingHybrid ManufacturingFurther Engineering Review
Compare 3D Sand Printing with Traditional PatternsYou do not need to have every item prepared before contacting us.
Conference Presentation
AFC 2023: Printed Moulds for New and Replacement Cast Components
At the 16th Asian Foundry Congress, Speed3D Mold presented its experience of using 3D sand printing to produce moulds for new and replacement cast components, including selected spherical feeder and helical sprue gating examples.
View AFC 2023 PresentationFrequently Asked Technical Questions
- Does Speed3D Mold print the final metal part?
- No. The binder-jetting process produces the sand molds and cores. The printed mold package is then used in the metal casting process to produce the component in the specified alloy.
- Can a project start without an original CAD file?
- Yes. A project can start from drawings, scan data, or an existing physical component. Where usable CAD data does not exist, the geometry is captured and reconstructed first through reverse engineering, subject to the condition of the reference component.
- When is 3D sand printing preferable to conventional tooling?
- It is generally most relevant for one-off or low-volume work, complex core packages and projects where no pattern exists. The comparison is project-dependent and is made against geometry, quantity, material, tolerance, inspection requirements and schedule.
- Can printed sand molds be used for replacement castings?
- Yes, where the replacement geometry can be established from drawings, scan data or an existing component and reviewed for castability. Documented replacement work using printed molds is described in the case studies and published technical work referenced on this site.
- What determines mold and core lead time?
- The condition of the available project data, the engineering review, mold and core complexity, the size of the mold package relative to the build volume and the current production schedule. Lead time is confirmed per project rather than stated as a general figure.
- Can Speed3D Mold provide casting simulation and metal casting?
- Yes. Casting simulation is applied where required for the project, and metal casting, machining coordination and inspection are carried out as part of the agreed scope rather than as separate print-only supply.
- What information is required for a quotation?
- A drawing, CAD file, scan data or photographs of the component, principal dimensions and approximate weight, the required alloy, quantity, machining scope, inspection requirements and the target delivery date.
- Is 3D sand printing suitable for repeat production?
- It can be used for repeat work, but for stable, higher-volume repeat production conventional or hybrid tooling may be more economical. The route is evaluated against the complete project requirement.
Discuss the Right Manufacturing Route for Your Casting
Share your drawing, CAD data, scan data or existing component. Our engineering team will review whether 3D sand printing, conventional tooling or a hybrid route is appropriate for the project.
