Reduce cost and time by 50% for reusable patterns of any complexity and size.
Up to 50%
cost reduction over conventional patterns
2x
faster pattern production
50x50x72"
(1270x1270x1828mm) single-piece patterns

Accelerate Casting Production with 3D Printed Patterns

The sand casting process is evolving thanks to the benefits and advantages offered by Additive Manufacturing (AM). By incorporating AM into your process, you can achieve faster, more cost efficient and more agile production of patterns and core boxes.

With 3D Systems additive manufacturing solutions and expertise, you can reduce production time for medium to large casting patterns from weeks to days without sacrificing size or design complexity.

Sand Casting part
In-house additive manufacturing has become our ‘secret sauce.’ It gives us the advantage over our competitors when it comes to tooling price, accuracy, speed of production, and the ability to modify existing jobs with lightning-fast turnaround times.
—Bob Helwer, Engineering Manager, Astech, Inc.

Solving Sand Casting Patterns and Cores Manufacturing Challenges with 3D Printing

  • Faster Time to Market

    To be competitive, foundries and pattern shops must meet demands for fast production of patterns and core boxes, while still delivering high quality parts and the ability to adjust designs quickly and cost-effectively. 3D Systems solutions enable lights out manufacturing processes that can print a pattern quickly with pellet extrusion 3D printing and then machine the surface during or after the printing process for smooth, accurate patterns and core boxes.

    Machine in-situ or post printing for smooth, accurate surface finish

  • Background image

    Machine in-situ or post printing for smooth, accurate surface finish

  • Design Complexity and Flexibility

    The layer-by-layer build of 3D printed casting patterns means foundries can quickly and inexpensively deliver what were previously impossible or difficult to produce geometries. Additive technology enables the creation of hidden voids, internal struts and blind holes that are beyond the geometric limitations of 6-axis CNC tooling. Gating, runners, and sprues can also be included.

    Print fast with pellet extrusion on our EXT Titan 3D Printers

  • Background image

    Machine in-situ or post printing for smooth, accurate surface finish

  • High Quality Castings

    Maintaining dimensional accuracy and ensuring pattern durability are key to sand casting success and metal part quality. Our additive manufacturing solutions for sand casting use durable and affordable materials proven to run for thousands of cycles with almost no visible wear.

  • Sand Casting Pattern

  • Reduced Costs

    Beyond minimizing waste with additive manufacturing efficiency compared to traditional subtractive methods, our 3D printing solutions use the most cost-effective, yet durable materials. Labor is further reduced with lights out manufacturing capabilities, the ability to produce single-piece large patterns that don't require assembly, and minimized finishing with sooth pattern surfaces, all contributing to reduced cost per part.

  • Grey, natural hybrid pellets on a neutral background

Your Partner for 3D Printed Sand Casting Patterns and Core Boxes

  • We Offer Complete Solutions

    • Powerful software for CAD design, reverse engineering, inspection and 3D printing
    • Multiple 3D printing technologies that can deliver from complex geometries with outstanding surface finish, up to very large parts with the highest material deposition speeds
    • Best-in-class materials, including a wide range of affordable, high performance pellets
    • Tailored hardware to meet your needs, including pellet extrusion and hybrid additive + subtractive systems

  • Small to Large Parts Capacity

    • Large build capacities, up to 1.82m in length
    • Ideal for large parts that would typically require extensive labor for assembly
    • Seamless workflows for parts that exceed build volume

  • Applications Consulting

    • Robust network of experts in the 3D Systems Application Innovation Group (AIG)
    • Leverage AIG's years of sand casting and additive manufacturing experience
    • Dedicated team provides hands-on training and consultation from ideation to implementation

Learn More About our Solutions for Sand Casting

EXT 800 Titan Pellet 3D printer

EXT 800 Titan Pellet

Unser industrieller Einstiegs-3D-Drucker mit Pelletextrusion und kompaktem Rahmen, der durch Standard-Doppeltüren passt.

EXT 1070 Titan Pellet

EXT 1070 Titan Pellet

Der Pelletextrusionsdrucker von 3D Systems ist in der Lage, mittel- bis großformatige Teile zu drucken. Er verfügt über ein Bauvolumen von 1070 mm x 1070 mm x 1118 mm (42 in x 42 in x 44 in).

EXT 1270 Titan Pellet

EXT 1270 Titan Pellet

Mit dem größten 3D-Drucker von 3D Systems können großformatige Teile mit einer Höhe von bis zu 1,80 m mittels direktem 3D-Druck mit Pelletzufuhr gedruckt werden.

Schwarze Kunststoffpellets

EXT Titan Pellet Materials

Große Auswahl an leistungsstarken und flexiblen kommerziellen, technischen Polymeren für den 3D-Druck

Do you want to discuss our solutions for foundries with an expert?

  • Application Innovation Group

    Unser Team kann Ihnen helfen, Ihre schwierigsten Herausforderungen bei Design und Produktion mit additiven Fertigungslösungen zu bewältigen. Gemeinsam ermitteln wir Ihren Bedarf und arbeiten mit Ihnen an der Optimierung Ihrer Entwürfe, dem Prototyping, der Validierung und der Definition eines Fertigungsablaufs.
    Weitere Informationen