3D Printed Sand Mold Castings
Digital design and patternless casting of prototypes, complex cores and obsolete castings
3D Printed Sand Mold Design and Pouring
3D Printed Sand Molds for Complex Cores
OK Foundry designs and pours 3D printed sand molds for complex short run iron castings and serial production of castings requiring 3D printed cores. 3D printed molds and cores are an economical solution for short run castings having multiple cores, complex cores, or difficult cores. 3D printed molds and cores can shorten the lead time for prototype or spare part castings, but tend to be most cost competitive for complex castings or small castings.
3D CAD Design
OK Foundry has complete 3D CAD/CAM design capabilities including the latest version of Solidworks to provide design support for 3D printed sand mold and core design. Additionally, OK Foundry has built a complete end to end CAD/CAM system including FeatureCAM for 3D toolpaths for CNC milling of foundry patterns and simulation of CNC machining of castings. Regardless of your native 3D CAD software platform, OK Foundry can support a fully digital 3D casting design and development program.
Mechanical Engineering Services for Casting Design
To make highly complex one-off prototype or antique engine castings feasible, OK Foundry works with Hunter Mechanical Design, LLC for casting and 3D printed mold design. Hunter Mechanical Design has developed expert 3D printed mold design skills working with OK Foundry on challenging casting projects like antique engine blocks and cylinder heads, and Hunter can provide complete Mechanical Engineering support including Finite Element Analysis (FEA), 2D and 3D engineering drawings for casting, machining and assembly for complete subcontracting of manufacturin engineering support.
3D Printed Sand Mold Galleries
Castings from 3D Printed Sand Molds
OK Foundry has been designing and pouring 3D printed sand molds since 2012, just two years after ExOne introduced the S-Max sand printer in 2010. Since that time, we have continuously improved our ability to design and pour 3D printed sand molds and cores to solve unique casting problems.
1912 Velie Engine Block
OK Foundry reverse engineered a 1912 Velie engine block and poured a new casting from 3D printed sand molds and cores. Laser scanning of the block was performed by Direct Dimensions, Inc. and the casting and printed molds were designed by OK Foundry. The Velie engine block had tight water jacket passages that required complex coring and to economically cast one engine block that was engineered over 100 years ago was a challenge only possible using 3D printed cores and molds and the foundry know-how of OK Foundry, also over 100 years in the making.
OK Foundry reverse engineered a broken elevator reel casting from a historic building in Philadelphia. By using 3D printed sand molds and cores the elevator reel could be cast with the spiral cable take up groove found on the original casting saving considerable machining time.