Expand your business - COLMEXThe ExOne binder jetting technology produces cores and molds made of...

Expand your business3D Core & Mold Printing

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The future of industrial development is placing high demands on foundries and supply companies.

Where cost management and feasibility of complexity are reaching their limits with conventional methods, 3D printing is at the very start of its virtually limitless potential.

3D Core & Mold Printing

Solutions for complexity and growing customer demands

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Strong growth for the future

The industry’s pressure to innovate is creating constant growth for 3D core and mold production

Solutions for feasibility and cost-effectiveness

International competition in the OEM industry is

creating a new, fast-growing business segment

for the casting industry. Where conventional

manufacturing methods can no longer compete

with the innovation and cost pressure demanded

by rising complexity, the ExOne 3D core and mold

production provides new solutions for innovation,

feasibility and cost-effectiveness.

Creating profitable business areas

As a result of the industry’s ambitious objectives to

constantly improve the performance of cast parts,

foundries are increasingly becoming solution pro-

viders at eye level with the client. The optimization

of wall thicknesses, the improvement in ergo-

nomics and the reduction of individual cast parts

are creating highly profitable business areas. It is

exactly these business areas where the precision

and problem-solving competence of the unique

ExOne technology really make a difference.

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Be ahead with 3D core & mold printing

› Enhances the value added chain and expands the core business of foundries

› Generates high profitability for prototype manufacturing and series production

› Creates fast and unique solutions especially for high-complexity projects

› Provides a competitive edge and development competencies in the face of

international competitive pressure

› Is a significant part of Industry 4.0

Industry sectors

› Automotive industry

› Construction indutry

› Aerospace

› Engineering

› Pump industry

› Rail industry

› Naval industry

› Defence industry

› Oil & Gas industry

› Wind power industry

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Freedom in Part Geometry

Unbeatable productivity for demanding and complex structures

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ExOne’s technology allows

unique, geometric freedoms

otherwise unaffordable or

impossible in conventional

mold production.

From prototypes to series production in just a few hours

Unique solutions for ultra-complex part geome-

tries and structures are at the very heart of 3D core

and mold printing. Whether for producing molds

previously impossible or for infinitely variable

core geometries. Now everything can be done

simultaneously – even in a single print. Where

prototype production used to take many weeks,

ExOne’s technology delivers in just a few days or

even hours.

High flexibility and responsiveness for a tremendous range of variants

Designed in a CAD today and delivered as a

finished prototype tomorrow. 3D core and mold

printing by ExOne ensures absolute flexibility

in the production of complex molds. There are

no limits to the rising industry demand for variant

versatility and individual customer solutions, or in

the production flexibility of international locations.

Gain in quality and production safety

ExOne’s 3D core and mold printing technology is

a gain in quality and production safety. Flexible

prototyping produces fast, high-quality results –

especially when testing sophisticated molds and

improving tolerances. And the surface quality is

likewise impressive. Getting rid of snap tabs and

seams translates into a huge quality improvement

of the end product.

Maximum output with maximum complexity

› Efficient results even with highly complex and delicate designs

› Entirely novel and previously unheard-of geometries and structures from a single piece

› Improvement of tolerances and surface quality

› Production flexibility even in the face of rising demands for variant versatility

› Responsiveness in meeting the requirements of international conditions regarding location

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Die ExOne-Technologie ist in der

Herstellung von komplexen For-

men ökonomisch und profitabel.

3D Kern- & Formdruck senkt

den Zeit- und Kostenaufwand

bei gleichzeitig höheren Mar-

gen.

Convincing Cost-Effectiveness

Profitability and the proof that less is truly more

High profit for high complexity

In the production of complex casting molds, the

ExOne technology is “best in class” with respect

to profitability and cost-effectiveness – and will

continue to do so in the future. Spending less time

and money on creating a sophisticated casting

mold otherwise impossible by existing processes,

results in an improved bottom line. At every step of

the value added chain.

Incremental service and higher price acceptance

The ExOne printing system makes you the perfect

solution provider for any client. Cores and molds

of high complexity or innovative standards have a

considerably higher value for your customers than

standard productions. This allows you to offer an

additional service while benefiting from higher

margins.

Decreases time and development costs

The ExOne technology has put an end to long

development times and high costs of prototype

manufacturing and serial production. Serial pro-

duction is highly efficient and economical – espe-

cially for highly complex products. At the touch of

a button, with the parameters coming straight from

the CAD, 3D core and mold printers provide fast

results in just a few hours or days instead of weeks

or months.

Reduction in operating costs

The list is long: savings of energy costs and person-

nel costs, reduction in procurement processes and

storage, minimal multi-piece molds, no assembly

of individual parts, no complicated tool changes

and no manufacturing costs for tools, no support

structures and structural panels – and many more

potential savings speak for ExOne 3D printing. In

addition, 3D production also permits innovative

mold packages enabling different casting orienta-

tions without any limits on filling. Including more

efficient riser and feeder locations can help cut

down on work processes and save valuable raw

materials.

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The ExOne technology is

economical and profitable

when producing complex molds.

3D core & mold printing reduces

time and cost while increasing

margins.

More profit and less costs

› Complexity increases the industry’s acceptance of higher prices

› Considerable time saving due to delivery in a few hours / days

instead of weeks / months (with the parameters coming directly from the CAD)

› Outstanding cost savings in development and prototype production

› Continuous savings in operating costs

› Optimization of consumables and raw materials

(also thanks to internal bionic structures, such as hatching)

3D core and mold printing by ExOne impresses twofold: for

cost-effectiveness

in prototyping

and for series

production of

highly complex

molds

COMPLEXITY

CO

STS

PER

PA

RT

Traditional Manufacturing

3D Core & Mold Printing

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Binder Jetting Technology

Precision and reliability thanks to unique printing technology

Indirect printing of ultra-complex part geometries

The patented ExOne binder jetting technology is a

globally unique procedure, developed especially

for rapid printing of ultra-complex part geome-

tries. The layer by layer process guarantees max-

imum precision while immediately turning digital

models into reality.

Building cores and molds layer by layer

The innovative print head and recoater (sand

distribution) facilitate high printing speeds.

Alternating layers of molding material (sand lay-

ers) and binder materials (industrial binders) are

applied in this process. The process is continually

repeated until the cores and molds are complete.

This way, almost any geometric property can be

realized which would otherwise be impossible with

conventional production processes.

Start layer:First the recoater applies 4-8 sand layers on the bottom of the jobbox.

Printing:The print head is selec-tively applying a first layer of binder on the activated sand.

New layer:The print platform in the jobbox is lowered by one layer height.

Recoating:The recoater is applying a new layer of activated sand.

Repeating: Steps 2-4 are repeated until the core/mold is finished.

Finishing:The unbound sand is removed from the jobbox and the sand mold/core is ready for use.

Various applications

› Prototypes & Product Development

› Serial Production of Complex Parts

› Exclusive Productions

› Reproduction of no longer available parts (Reverse Engineering)

› Parts consisting of Composite Materials (Wash-out Tooling)

The ExOne binder jetting

technology produces cores

and molds made of molding

materials and special binders

in an indirect printing process

– directly from the CAD data.

Flexible, precise and in the

shortest possible time.

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Solutions

for individual challenges

Cast products come with different performance and profitability requirements in every sector of the industry.

ExOne focuses strictly on your objectives.

From an understanding the complexi-

ty requirements and envisaged casting

materials to an understanding of long-

term, economic objectives all the way to

complete integration in existing produc-

tion processes and a new future for your

company.

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Consultation & Commissioning

Experts for change management and technology integration

Integrating a new future for your company

The introduction of 3D core and mold printing technology means change and development in the

corporate organization. The ExOne experts support you in three phases during the first step: the planning

of your change management process, the development of short-term and long-term future scenarios,

and purchasing planning as a whole.

Expertise for optimum production conditions

Our experts understand the individual require-

ments in the different industries and will work with

you to analyze all the requirements demanded of

the casting products you are planning to produce.

Allow us to assist you with your competence infea-

sibility analysis and efficiency increases to make

you ready for the the cutting edge in research and

development

From planning to comissioning

We ensure flawless preparation for technology

integration from the very beginning.

The ExOne experts will accompany you during the

entire implementation, from the planning to the

start-up, and will hand over the finished production

process as soon as your employees are trained

and qualified.

The ExOne experts will accompany the entire integration process

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joint anal-ysis of your operation and your economic objectives

Definition of target products and casting materials

Prototype cores and molds from the ExOne Adoption Center

Optimization of cost- effectiveness with external service providers

Integration of your own ExOne 3D core and mold printing production

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Binders & Molding Materials

Combined solutions for any casting requirement

FURANCold Hardening Binder System

CHP Cold Hardening Phenol

Cold Hardening Binder SystemHHP Hot Hardening Phenol

Hot Hardening Binder SystemSILICATEInorganic Binder System

Casting Material Casting Material Casting Material Casting Material

Steel, Iron, Non-ferrous Metal, Aluminum Steel, Iron, Non-ferrous Metal, Aluminum, Bronze Steel, Iron, Non-ferrous Metal, Aluminum, Bronze Non-ferrous Metal, Aluminum

Characteristics* Characteristics* Characteristics* Characteristics*

Hot strength:

Filigree character:

Strength/Loadability:

Finishing:

5 – 10 **

5 – 6

7 – 8

1 – 2

Hot strength:

Filigree character:


Finishing:

7 – 10

9 – 10

7 – 8

9 – 10

Hot strength:

Filigree character:


Finishing:

9 – 10

10

10

9 – 10

Hot strength:

Filigree character:


Finishing:

3 – 4

9 – 10

6 – 7

9 – 10

Molding Material Molding Material Molding Material Molding Material

Silica Sand / Synthetical Sand Silica Sand / Synthetical Sand Synthetical Sand Silica Sand / Synthetical Sand

Additives Additives Additives Additives

Magnesium Inhibitor / Iron Oxyde None None None

Thermal Postprocessing Thermal Postprocessing Thermal Postprocessing Thermal Postprocessing

None Optional Necessary Necessary

* Range 1-10: 10 corresponds to the best suitability.

** With Additive

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S-Print3D Core & Mold Printing System

All-rounder for prototypes and small series

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Output

120 units / jobbox

7-12 production time (h)*

Binder Systems

Furan | Silicate | CHP | HHP

Characteristics

Use: stand-alone solution

External dimensions (m): 2.54L × 3.27B × 2.86H

Build volume (l): 160

Build dimensions (mm): 800 × 500 × 400

Possible layer heights (mm): 0.24 – 0.38

Layer time (sec.): 20 – 25

* Depending on sand binder

Control cabinet

Jobbox• optional external roller conveyor• optional additional jobbox

Twin source sand mixer filled with vacuum or screw conveyor

Operating panelLoading/unloading station

The S-Print combines a compact structure with an extremely versatile range of applications. By giving you

absolute flexibility in selecting any binder system available at ExOne, S-Print is your perfect solution for

virtually all casting materials. Making it the right choice for prototypes and small series.

As with all ExOne 3D core and mold printers, cores and molds can be created from CAD data quickly and

without the need for tools.

150 × 150 × 50 mm

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S-Max3D Core & Mold Printing System

Productivity for all cold hardening binder systems

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Jobbox• for loading & unloading procedures• on motorized roller conveyor• optional second jobbox

Control cabinet

Operating panel

Fluid connections

Output

1008 units / jobbox


Binder Systems

Furan | CHP

Characteristics

Use: stand-alone solution

External dimensions (m): 10.40L × 3.52B × 2.86H **





The S-Max offers a robust and reliable solution for all cold hardening binder systems. It is suitable for

almost all casting materials. Large and complex cores and molds can be realized even more quickly and

reliably. With the larger construction platform and double jobbox, the S-Max produces any prototype

requirement and whole series with efficiency and performance.

150 × 150 × 50 mm

* Depending on sand binder

** With 2 Jobboxes

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S-Max+3D Core & Mold Printing System

Specialist for high flexibility for compounds

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Output

864 units / jobbox


Binder Systems

HHP | Silicate

Characteristics

Use: system (incl. microwave)

External dimensions (m): 3.86L × 3.51B × 3.47H





The S-Max+ is perfect for series and prototype production of inorganic cores and molds with a high

degree of complexity. Equipped with HHP, its 3D prints are perfect for high-temperature casting. With its

special feature for inorganic materials, it provides particularly high-quality printing results thanks to its

reduced gas emissions. Its modular concept offers a high degree of flexibility for countless variations in

the facility network and Industry 4.0.

150 × 150 × 50 mm


Operating panel

Pedestal

Jobbox

* Depending on sand binderTurntable

Microwave

Roller conveyor

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3D Core & Mold Printing Systems

Technical characteristics comparison

S-Print S-Max S-Max+

Binder Systems

Furan | Silicate | CHP | HHP Furan | CHP Furan | HHP

Characteristics

Use: stand-alone solution stand-alone solution system (incl. microwave)

External dimensions (m): 2.54L × 3.27B × 2.86H 10.40L × 3.52B × 2.86H * 3.86L × 3.51B × 3.47H

Build volume (l): 160 1260 1080

Build size (mm): 800L × 500B × 400H 1800L × 1000B × 700H 1800L × 1000B × 600H mm

Possible layer heights (mm): 0.24 – 0.38 0.26 – 0.38 0.24 – 0.38

Layer time (sec.): 20 – 25 30 – 35 35 – 40

* With 2 jobboxes

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Service

Individual and rapid full service for high productivity and qualityExOne Adoption Center for test productions

The EAC (ExOne Adoption Center) is the first stop

for the introduction of 3D technology into your

company, and for the integration of the system

into existing processes. EAC allows you and our

specialists to print all component geometries for

the planned cores and molds, and to test them in

detail. Depending on the required complexity and

the casting materials used, all binder types and

molding substances can be used.

ExOne Academy for professional team training

Practical knowledge, compact and directly from

the experts: The Academy Training equips your

team for dealing professionally with ExOne 3D

technology – directly and with easy-to-understand

information. Our experts will guide your employ-

ees through a condensed training programme with

the aim of practicable application and rapid imple-

mentation of production objectives. The training

programme offers tried-and-tested learning

methods and modern learning media,

so that your team can master the technology

as easily as possible.

After-sales service and quality assurance

Installation and commissioning

Our service technicians will rapidly integrate and

implement the ExOne 3D printer. Professional

assembly and installation are based on almost 20

years of manufacturing experience. Consideration

of safety aspects plays a central role here.

Call-out

If you need a service technician on-site, you can

be sure that we’re standing by to provide service.

Around the clock if needs be. A concept coordi-

nated to you contains individual reaction times,

ensuring your system availability – from workday

support to 24-hour service.

Telephone support

Do you need a hotline to us? As part of our individ-

ual service agreements, you will receive telephone

support. Through our in-house helpdesk, you

will access our experts, who can provide you with

guidance over the phone around the clock.

Maintenance

Our active maintenance management guarantees

you get a high production quality. Maintenance is

carried out according to our test record specifi-

cations. With regular maintenance, any wear and

tear can be recognised in advance, documented

and immediately rectified as required.

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Global Company

Rely on stability and international competence –with the market leader in 3D indirect printing

ExOne and the unique binder jetting technology

are world leaders in the field of industrial, additive

production procedures. Since 1999, the one-time

start-up in the manufacturing of 3D core and mold

prints has developed from a handful of engineers

into a global technology developer with service

and support networks in Germany, the USA and

Japan.

As a market-listed technology company and

future-focused innovator, ExOne is the perfect

partner for any industrial manufacturer with its

international sites. The company supplies leading

customers from the automobile sector, pump

manufacturing, aerospace industry, the energy

sector and plant construction.

Success story from the idea to the market leader

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3130

USA Mid-West

ExOne 2341 Alger DriveTroy, MI 48083 USA

Phone: +1 248 740 1580

USA Mid-Atlantic

ExOne 127 Industry BoulevardNorth Huntingdon, PA 15642 USAPhone: +1 877 773 9663Phone: +1 724 863 9663

USA North

ExOne North America Research Facility66850 Executive DriveSt. Clairsville, OH 43950USA

Phone: +1 740 695 0397

Germany

ExOne GmbHDaimlerstraße 2286368 GersthofenGermany

Phone: +49 821 65063-0

Japan

ExOne KK Japan161-5 HaneoOdawara-shi, KanagawaJapan 256-0804

Phone: +81 465 44 1303

ExOne EuropeExOne America ExOne Asia

Contact

3130

Comple ity is simple.

ExOne GmbH

Daimlerstraße 22

86368 Gersthofen

Germany

Phone: +49 821 65063-0

Fax.: +49 821 65063-11

E-Mail: [email protected] www.exone.com 09

/20

18 –

03.

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