Systemized prototype manufactoring for increased competitiveness [SPÖK]

Purpose and goal

Understand the status of the technology and the level of knowhow of 3D-printing in Swedish foundries. Knowledge is low regarding the technique to make moulds and cores in sand. Only one foundry uses this technology for the production of prototypes/parts. Meeting the target, keep the competitiveness of the Swedish foundries, requires that Swerea is granted projects in which they can modify Swedish sand to the 3D-printing and create rules for adjustment of the CAD model compared to final component.

Results and expected effects

Foundries abroad use the technology of 3D printing in the sand! Audi, BMW, MAN, VW etc. using cores and moulds made in 3D prints. The sub-contractor that can supply the fastest prototype will get the order not necessary is the cheapest, according to casting buyers. CAD files are still too simple and without compensation for distortion. It requires more knowledge how to correct geometries in order to optimize time from concept to production. Research at Swerea can give the Swedish foundry industry the necessary skills required to become a preferred supplier. Casting trial not performed.

Approach and implementation

Established State of the art of the technology, vendors, availability, literature study and 3D-CAD model. Status is taken from interviews and literature studies. A market research has provided vendors. Availability for the Swedish foundries has been investigated by visiting two vendors in Germany. Literature studies have been conducted to find the limitations of technology and opportunities. A CAD model for evaluation of distortion has been developed and the order for sand mould is sent to vendor.