In today's era of rapid development of manufacturing industry, traditional foundries are facing increasingly fierce market competition and constantly improving product quality requirements. As an innovative technology, sand 3D printers are becoming the key to improving competitiveness and upgrading foundries. This buyer's guide is designed to provide comprehensive, in-depth guidance to managers of traditional foundries to help them make informed purchasing decisions.

I. Understanding your own needs

Analyzing the current situation of factory production

• Evaluation of traditional process: Carefully review the traditional casting process currently used in the factory, including the way the molds are made (e.g., wood molds, metal molds, etc.), the molding process (hand molding or machine molding), and the process of melting and pouring. Evaluate the time, labor, and material costs as well as the problems associated with each process. For example, traditional wooden mold making can take weeks and is prone to dimensional deviations and damage; hand molding is labor-intensive, inefficient and inconsistent in quality.
  • Product Characterization: Define the type of castings that the plant will mainly produce, whether they are castings with simple structures or castings with complex internal cavities, thin-walled structures or finely curved surfaces. Determine the size range of the castings, from small castings of a few centimeters to large castings of several meters. At the same time, analyze the requirements for casting accuracy, for example, certain aerospace castings may need to be millimetre accurate or even higher. In addition, the material of the casting should be considered, which may vary from material to material in terms of casting process and equipment requirements.
  • Production scale considerations: Evaluate the daily production scale of the plant, including monthly or annual casting production. Understand the characteristics of the production orders, whether it is a large number of single product production or small quantities of multi-species production. For the peak and trough production capacity changes also need to have a clear understanding, which will affect the selection of equipment and production arrangements.

Defining goals and desired improvements

• Cost control objective: If cost reduction is the main objective, the cost composition of each link needs to be analyzed. Mold production costs account for a large proportion of the traditional process, and sand 3D printers can eliminate the mold production process, significantly reducing this part of the cost. At the same time, considering labor costs, 3D printers have a high degree of automation, which can reduce the reliance on labor. In terms of material costs, although 3D printing requires specific sand and binder, material utilization can be improved by precisely controlling the amount of material used, and waste can also be reduced through the re-cycling of sand. In addition, the 3D printing process can optimize the structure of sand molds and reduce the amount of sand used through lightweight design. For example, for a medium-sized foundry, by introducing sand 3D printers, the cost of molds may be reduced by 40%, the labor cost by 30%, and the material cost savings by about 20%.
  • Efficiency Improvement Requirement: For foundries pursuing productivity improvement, focus on the molding speed of the equipment. Sand 3D printers can print a complex sand pattern in a few hours, compared with the traditional mold making and molding weeks, a significant increase in efficiency. In addition, 3D printers can print multiple sand molds at the same time, or zone printing on a large sand mold, greatly reducing the overall production cycle. For example, after the introduction of 3D printers in an automotive parts foundry, the product development cycle has been shortened from several months to a few weeks, and production efficiency has been increased by more than 50%.
  • Quality Improvement Expectations: The ability of sand 3D printers to print with high precision is critical when higher quality products are required. It can precisely control the size and shape of the sand mold, reducing dimensional deviations and surface defects in the castings. At the same time, due to the stability and consistency of the printing process, it can improve the internal quality of castings and reduce defects such as porosity and slag entrapment. For example, in some high-end equipment manufacturing fields, the scrap rate of 3D printed sand castings has been reduced from 10% in the traditional process to less than 2%, and the product quality has been greatly improved.
  • Flexibility enhancement direction: for foundries that need to respond to small batch, multi-variety production needs or personalized custom orders, the advantages of sand 3D printer is particularly obvious. It does not need to make physical molds, can be quickly switched to produce different products according to the digital model, greatly improving the flexibility of production. For example, some art foundries or customized parts production enterprises, through the 3D printing technology can meet the diverse needs of customers, broadening the market space.

Evaluation of key features of sand 3D printers

Printing Accuracy

• Impact of precision on casting quality: Printing precision directly determines the dimensional accuracy and surface quality of castings. High-precision printing can ensure that the dimensional deviation of the castings is within a very small range and meet the strict assembly requirements. In terms of surface quality, high-precision printing can reduce the roughness and defects on the surface of the casting and improve the appearance quality of the casting. For example, in the production of key components such as engine blocks, high-precision sand molding can ensure the precision of the fit between the piston and the cylinder block and improve the performance and reliability of the engine.
  • Choosing the right precision equipment: First, the required precision level is determined according to the design requirements and usage scenarios of the product. For some common mechanical parts, millimeter-level accuracy may be sufficient; while for high-precision castings in aerospace, medical devices and other fields, sub-millimeter or even higher accuracy may be required. Secondly, understand the precision parameters of different devices, including layer thickness and dimensional error range. You can refer to the technical information and actual test data provided by the manufacturer, while exchanging experiences with other users. For example, 3DPTEK sand 3D printers are capable of achieving a dimensional accuracy of ±0.3mm, which is suitable for the production of castings with high accuracy requirements.
  • Comparison of different precision level equipment and applicable scenarios: low-precision equipment is usually relatively low-priced, applicable to some production scenarios that do not require high precision and focus on cost control, such as ordinary construction machinery castings. Medium-precision equipment balances price and performance, and is suitable for the production of most industrial parts. High-precision equipment, on the other hand, is suitable for high-end manufacturing areas, such as aerospace, precision instruments, etc., but the price is relatively high. For example, in the production of automobile engine cylinder head, medium-precision equipment can meet the basic production requirements; for aero-engine blades and other high-precision castings, you need to choose high-precision equipment.

Print Size

• Print size in relation to production scale and casting size: For large foundries, equipment capable of printing large castings is often required to meet production demands. For example, in the production of large ship engine block, may require several meters or even larger size printing equipment. For small foundries or production of small castings of enterprises, the smaller size of the equipment may be more economical and practical. At the same time, the print size also affects the footprint and space requirements of the equipment, which need to be taken into account in factory planning.
  • Selection strategy: according to the factory's production planning and market positioning to determine the required print size. If the main production of large castings, you need to choose a larger print size of the equipment; if the main small castings, you can choose small or medium-sized equipment. Also consider the future development needs, set aside a certain amount of capacity expansion space. In addition, pay attention to whether the equipment print size can be flexibly adjusted, for example, some equipment can be replaced by the printing platform, or even no sand box printing to adapt to the production of castings of different sizes. For example, a medium-sized foundry plans to expand into the field of large-scale casting production in the future, then in the selection of equipment, you can give priority to those with upgradable print size or modular design of the equipment in order to expand in the future according to demand.

Equipment stability and reliability

• The importance of stable operation of equipment: in casting production, the stability of equipment is crucial. Once the equipment failure, it may lead to production interruption, affecting the delivery date, and bring great economic losses to the enterprise. Especially for the continuous production of foundry, equipment for a long time stable operation is to ensure production efficiency and product quality basis. For example, in the automotive parts casting production line, if the 3D printer frequently fails, it will lead to production line stagnation, affecting the whole car production schedule.
  • Examine methods of stability and reliability:
    • Check the manufacturer's quality control system: understand the manufacturer's production quality management process, including raw material procurement, parts processing, assembly and commissioning and other aspects of quality control measures. A manufacturer with a perfect quality control system is usually able to produce more stable and reliable quality equipment. For example, some well-known manufacturers of each component are strictly quality testing to ensure that it meets the high standards of quality requirements.
    • User Word of Mouth: Communicate with users who have already used the device to understand their evaluation of the stability and reliability of the device. The actual use experience of users is the most direct and real feedback. You can participate in industry exhibitions, join professional communities and other ways to establish contact with other users to get their opinions and suggestions. For example, some foundries will prioritize those brands with good reputation in the same industry when choosing equipment.

Software Support

• Excellent software features and functions:
  • Model Processing: Powerful 3D printing software can efficiently process complex casting models, including model repair, optimization, slicing and other functions. For example, for some models imported from CAD software that may be defective or unsuitable for printing, the software can automatically detect and repair these defects to ensure that the model can be printed smoothly.
  • Printing parameter setting: The software should provide a wealth of printing parameter setting options, such as printing speed, layer thickness, nozzle temperature, binder dosage and so on. Users can according to different casting requirements and material properties, precise adjustment of these parameters to obtain the best printing results. For example, for thin-walled castings, it may be necessary to adjust the layer thickness and printing speed to ensure the strength and precision of the sand mold.
  • Production process management: the software should also have production process management functions, including order management, task scheduling, equipment monitoring. This can help foundries realize efficient production management and improve production efficiency. For example, through the software can real-time monitoring of the operating status of the equipment and printing progress, rationalize the arrangement of production tasks to avoid production congestion.
  • Evaluate software for ease of use, functional integrity, and compatibility with devices:
    • Ease of use: the operating interface of the software should be simple and clear, easy to get started. With an intuitive graphical interface and clear operating procedures, even non-professional technicians can quickly master. Ease of use can be assessed by trying out the software or viewing a demo video of the software in action. For example, some software adopts a wizard-type operation process, users only need to follow the prompts step-by-step operation to complete the entire printing process.
    • Functional completeness: Check whether the software has the basic functions mentioned above such as model processing, printing parameter setting, production process management, and whether there are some special features such as automatic optimization algorithms, remote control and so on. The more complete the function, the higher the applicability and flexibility of the equipment. For example, some software has intelligent optimization algorithms, which can automatically adjust the printing parameters according to the shape and structure of the casting to improve printing efficiency and quality.
    • Compatibility: Ensure that the software has good compatibility with the device and can drive the device stably for printing. Also consider the compatibility of the software with other design software, such as CAD software, for smooth model import and processing. You can check the software's technical documentation or consult with the manufacturer to find out what file formats and software interfaces it supports. For example, some software supports common file formats such as STL, OBJ, etc., and can work seamlessly with most CAD software.

III. Cost and return on investment analysis

Equipment purchase costs

• Price range for different brands and configurations: The price of sand 3D printers varies depending on the brand, technology level, print size, accuracy and other factors. Generally speaking, the price of equipment from European and American brands is relatively high, and may be in the millions or even tens of millions of dollars; the price of equipment from Chinese brands is relatively low, and may range from hundreds of thousands of dollars to millions of dollars depending on different configurations. For example, some high-end European and American equipment with advanced technology and excellent performance, but the price is very expensive; and some of China's emerging brands of equipment in the price-performance ratio is more advantageous, such as 3DPTEK, this brand is more famous in China, the equipment is very cost-effective, while 3DPTEK operates its own almost 10 foundries, but also dozens of foundry enterprises in China to provide Equipment, it can be said that the market has been strictly verified, is a very good choice.
  • Analysis of the reasons for price differences:
    • Technology level: Advanced printing technology, high-precision control system, stable mechanical structure, etc. will increase the cost of the equipment. For example, equipment using laser sintering technology is usually more expensive than equipment using ordinary binder jetting technology, because laser sintering technology offers higher precision and better sand strength.
    • Brand influence: well-known brands usually invest more in research and development, production, after-sales service, etc., and their brand value will also be reflected in the price of equipment. Some brands with many years of industry experience and good reputation, often able to provide more reliable equipment and better service, but the price is also relatively high.
    • After-sales service: perfect after-sales service system, including equipment installation and commissioning, training, maintenance, technical support, etc., will increase the manufacturer's operating costs, which is reflected in the price of equipment. Some manufacturers provide 24-hour online technical support, rapid response maintenance services, etc., which will have an impact on the price.

operating cost

• Cost of supplies:
  • Sand: Sand used in sand 3D printers typically needs to meet certain grain size, shape, and strength requirements. Prices for different qualities of sand vary and fluctuate with market supply and demand. For example, some high-strength, low-dust specialty sands may be relatively expensive, but can improve the quality of the sand pattern and printing results.
  • Binder: Binder is the key material to bond the sand together to form the sand mold, and its price will also affect the operating cost. Different types of binder differ in performance and price, and need to be selected according to actual needs. At the same time, the amount of binder will also affect the cost, some advanced printing technology can reduce the amount of binder used to reduce costs.
  • Energy consumption cost: the equipment will consume electricity during operation, and its energy consumption cost is related to the power of the equipment, running time, electricity price and other factors. When choosing equipment, you can focus on the energy efficiency ratio of the equipment and choose energy-saving equipment. For example, some devices use advanced energy-saving technologies that can reduce energy consumption under the premise of ensuring print quality. High-power devices usually consume more energy per unit of time, and if the device runs continuously for a long time, the cost of energy consumption will increase significantly. And the difference in electricity prices in different regions will also have an impact on the cost, such as industrial power consumption in concentrated areas may have certain preferential policies on electricity prices, need to take these factors into account to accurately assess the cost of energy.
  • Equipment Maintenance Costs: Regular maintenance and upkeep of equipment is necessary to ensure its normal operation and incurs certain costs. Including the replacement of wearing parts, equipment cleaning, calibration and other aspects of the cost. Some manufacturers will provide equipment maintenance service packages, foundries can choose according to their own situation. At the same time, the reliability and stability of the equipment will also affect the maintenance costs, low failure rate of the equipment maintenance costs are relatively low. For example, some equipment using high-quality components and advanced design, reducing the frequency of replacement of wear parts, reducing maintenance costs.

Return on investment assessment

• Cost savings analysis:
  • Mold Cost Savings: As mentioned earlier, the cost of making molds in a traditional casting process is high, whereas sand 3D printers eliminate the need to make physical molds, which can significantly reduce this cost. Mold cost savings can be assessed by calculating the difference between the cost of making a traditional mold and the cost of 3D printing a sand mold. For example, a complex casting can cost tens of thousands of dollars to make the mold, whereas with a 3D printed sand pattern, this cost can be reduced by more than 80%.
  • Labor Cost Savings: Due to the high degree of automation in 3D printers, the reliance on labor is reduced. Labor cost savings can be calculated by comparing the amount and cost of labor in a traditional process to the labor requirements with the adoption of 3D printing. For example, a traditional casting line may require dozens of workers for mold making, molding, etc., whereas with the adoption of 3D printers, only a few operators may be needed for equipment monitoring and maintenance, and labor costs can be reduced by about 50%.
  • Material Cost Savings: Material costs can be reduced by accurately controlling the amount of material used and improving material utilization. For example, while traditional molding processes may produce large amounts of waste sand and scrap, 3D printing can reduce waste by accurately controlling material usage based on the model. At the same time, some 3D printed materials can be recycled, further reducing costs.
  • Increased revenue from efficiency gains:
    • Reduced cycle time: Sand 3D printers can significantly reduce product development and production cycles. For some products that need to be on the market urgently, early delivery can result in a higher market price and competitive advantage. The value of the efficiency gains can be assessed by calculating the additional benefits of delivering products earlier. For example, by adopting 3D printing technology, an automotive parts foundry shortened the development cycle of new products from 6 months to 2 months, and entered the market ahead of schedule, gaining a higher market share and sales revenue.
    • Increased capacity: Efficient operation of the equipment and rapid prototyping capabilities can increase the capacity of the plant, thereby increasing sales revenues. The increased capacity and corresponding sales revenue can be projected based on the plant's production schedule and market demand. For example, if a foundry was producing 1,000 castings per month and the introduction of 3D printers increased capacity to 1,500 castings, and assuming a profit of $100 per casting, the increase in profit would be $50,000 per month.
  • Calculation of the payback cycle: The feasibility of the investment is assessed by calculating the payback cycle, taking into account factors such as equipment purchase costs, operating costs, cost savings and increased revenue. The payback cycle refers to the time it takes from the time the equipment is put into use to the time it takes to recover the full investment. For example, assuming that the purchase cost of a sand 3D printer is $2 million, and that cost savings and increased revenue total $800,000 per year, the payback cycle will be about 2.5 years. The potential impact of market changes, technology updates, and other factors on the payback cycle also needs to be considered in order to make a more accurate assessment.

IV. Market research and brand selection

Collecting market information

• Industry exhibitions: Attending foundry industry exhibitions at home and abroad is an important way to get information about the sand 3D printer market. The exhibition can directly contact with many equipment manufacturers to understand their latest products and technologies. At the exhibition, you can have in-depth communication with the technical personnel and sales staff of the manufacturers to obtain detailed product information and quotations. At the same time, you can also observe the live demonstration of the equipment, visualize the performance of the equipment and the operation process. For example, in some large international foundry exhibitions, there will be well-known manufacturers from all over the world to display their latest equipment and technology, providing foundries with a wealth of choices.
  • Professional websites: there are many professional casting equipment websites and industry forums, which gather a large amount of equipment information, user reviews and technical articles. By browsing these sites, you can understand the characteristics of different brands of equipment, user feedback and market trends. Some sites also provide equipment comparison and selection tools to help users better choose the right equipment for themselves. For example, on some professional websites, you can find detailed parameter comparisons of different brands of sand 3D printers and real user reviews, which provide reference for purchasing decisions.
  • User forums: Join user forums or communities in the foundry industry to exchange experiences with other foundry users. These users usually share their actual experience of using different equipment, the problems they encountered and the solutions. Their experiences and suggestions are very valuable for new users and can help avoid some common mistakes and pitfalls. For example, in some forums, users will share information about the actual use of the equipment, the quality of after-sales service, etc., which can provide reference for other users when choosing equipment.

Assessing brand reputation

• Manufacturer qualifications: Check the qualification certificates and honorary awards of the equipment manufacturers to understand their status and influence in the industry. For example, some national specialties and new "small giants" enterprises, high-tech enterprises, with ISO quality management system certification, etc., these qualifications prove that the manufacturer's strength in technology research and development, production management and other aspects. Honors and awards, such as the industry's scientific and technological innovation awards, excellent product awards, etc., also reflects the manufacturer's products in the technology and quality has been recognized.
  • Production experience: Manufacturers with rich production experience are usually more secure in product quality and after-sales service. You can find out how long the manufacturer has been engaged in the production of sand 3D printers, the scale of production and past project experience. A manufacturer that has been in the industry for many years and has provided equipment and solutions to many foundries is often more trustworthy. For example, certain manufacturers have been in the 3D printing and casting field for decades and have accumulated a wealth of experience, enabling them to provide personalized solutions based on the needs of different foundries.
  • Technology R&D strength: focus on the manufacturer's technology R&D investment and innovation ability. Advanced technology is a guarantee of equipment performance and quality, whether the manufacturer has its own R & D team, patented technology and cooperation with scientific research institutions can be used as a basis for assessment. For example, some manufacturers continue to invest in R & D funds, the introduction of new printing technology and features to meet the changing needs of the market, such manufacturers are more forward-looking in technology.
  • Market share and user evaluation: Knowing the market share of the brand's equipment can reflect its popularity and competitiveness in the industry. At the same time, by checking the evaluation of other users, you can get the real feedback about the quality, performance and after-sales service of the equipment. You can search online for user reviews, consult industry experts or directly contact other foundries to learn how they feel about the use of the brand's equipment. For example, if a brand of equipment in the market has a high share and the user evaluation is generally good, then it means that the brand is excellent in all aspects.

Field trips and prototype testing

• Field inspection: If the conditions allow, it is recommended to go to the equipment manufacturer for field inspection. You can visit the manufacturer's production workshop to understand its production process, quality control process and the advanced degree of production equipment. Observe whether the manufacturer's production management is standardized, and how the technical level and work attitude of the staff. At the same time, you can also have an in-depth communication with the technicians and managers of the manufacturers to understand their technical strength and service concept. For example, in the production workshop, you can check the assembly process of the equipment, the quality of the parts and the quality inspection link in the production process.
  • Prototype testing: Seeking to conduct prototype testing is a very important step. Prototype testing at the manufacturer or your own factory, inputting the actual casting model into the equipment, observing the printing process of the equipment, the quality of the sand mold, and the stability and reliability of the equipment. Through the prototype test, you can visualize whether the equipment meets your production needs and quality requirements. In the testing process, pay attention to record the printing time, sand accuracy, surface quality and other key data, and compare them with the technical parameters provided by the manufacturer. For example, you can prepare some representative models of complex castings for testing and observe the performance of the equipment in handling complex structures. Remember, this is very important, if you temporarily can not visit the site, even if you have to pay the cost (pieces are not big, generally manufacturers will be free to play, or at cost to help you play) but also to strive to let the manufacturer to print samples, which is the most intuitive understanding of the equipment.

V. After-sales service and technical support

After-sales service content

• Equipment installation and commissioning: the installation and commissioning of the equipment is the basis for ensuring the normal operation of the equipment. Excellent after-sales service should include a professional installation team to ensure that the equipment can be properly installed and initial commissioning and calibration. During the installation process, the basic structure and operation methods of the equipment should be explained to the user so that the user can initially understand the equipment. For example, the installers will reasonably arrange the installation position of the equipment according to the actual layout of the factory and the production demand, and carry out the connection and debugging of electrical and mechanical aspects.
  • Training: Comprehensive training services are crucial for users. The training content should include the operating skills of the equipment, the use of software, routine maintenance knowledge and common troubleshooting methods. Training can be divided into on-site training and online training in two forms to meet the needs of different users. For example, on-site training can be carried out after the completion of equipment installation, face-to-face guidance by professional trainers; online training can be through video tutorials, online classrooms and other ways to allow users to learn anytime, anywhere.
  • Maintenance: Timely and efficient maintenance service is the guarantee of long-term stable operation of the equipment. After-sales service should include regular equipment maintenance, such as cleaning, lubrication, inspection, etc., as well as in the event of equipment failure can quickly respond and repair. Manufacturers should provide sufficient spare parts inventory to ensure that damaged parts can be replaced in a timely manner during the maintenance process. For example, when equipment malfunctions, the after-sales service team should arrive at the site within a specified period of time to diagnose and repair the problem and minimize the impact of equipment downtime on production.
  • Software upgrade: With the continuous development of technology, the software of the equipment also needs to be upgraded and optimized. After-sales service should include regular software upgrade services to improve the performance and functionality of the equipment. Software upgrades can be carried out remotely through the network or by technicians at home to ensure a smooth and safe upgrade process. For example, the new software version may add some new functions, such as optimizing printing algorithms, improving printing speed and precision, etc., to bring users a better experience.

The Importance of Technical Support

• Solving technical problems: In the process of using the equipment, you may encounter various technical problems, such as the optimization of printing parameters, the improvement of the quality of the sand pattern, and the compatibility problems with other equipment. Professional technical support team can provide timely solutions to help users solve these problems and ensure smooth production. For example, when encountering the problem of substandard printing accuracy, the technical support staff can analyze the printing parameters, equipment status and other factors to give the corresponding adjustment recommendations to improve printing accuracy.
  • Optimized printing parameters: Different castings and production environments may require different printing parameter settings. Technical support personnel can provide optimized printing parameters according to the specific needs of the user and the actual situation, in order to achieve the best printing effect and production efficiency. For example, for some complex structure castings, technical support personnel can adjust the layer thickness, nozzle moving speed, binder dosage and other parameters according to its characteristics to improve the quality and strength of the sand mold.
  • Provide process improvement suggestions: With the accumulation of production experience and technological progress, process improvement is an important way to improve production efficiency and product quality. The technical support team can provide suggestions and solutions for process improvement according to the latest development of the industry and the actual situation of users. For example, by optimizing the production process and improving the molding method, etc., the overall production level of the foundry can be improved.

VI. Summary and recommendations

Summarize buying points and considerations

• Clear demand: Before purchasing, you must have a clear understanding of the current production status of their own factories, product characteristics, development planning, etc., clear their needs and expectations of the direction of improvement, so that you can choose the most suitable for their own equipment.
  • Comprehensive assessment of equipment characteristics: from the printing accuracy, print size, device stability, software support and other aspects of the equipment to carry out a comprehensive assessment to ensure that the performance of the equipment can meet the production requirements.
  • Consideration of cost and return on investment: not only should we focus on the purchase cost of the equipment, but we should also give full consideration to factors such as operating costs, cost savings and increased revenues, and calculate the return on investment cycle to ensure the feasibility of the investment.
  • Emphasis on brand reputation and after-sales service: choose manufacturers with good brand reputation, rich production experience and strong technical research and development strength, and at the same time to ensure that manufacturers can provide perfect after-sales service and technical support.

Encourage informed decision-making

• Traditional foundry in the face of equipment renewal and technological upgrading, to be brave enough to try new technologies, new equipment. Sand 3D printer as an innovative technology, can bring great changes and enhancement for the foundry. However, when making a purchase decision, we should consider all aspects of the factors, conduct sufficient market research and analysis, and manufacturers to carry out in-depth communication and exchange.

It is hoped that managers of traditional foundries can make wise purchasing decisions based on this buying guide, taking into account the actual situation of their own factories, introducing sand 3D printers suitable for them, enhancing the competitiveness of their factories, realizing sustainable development, winning the first opportunity in the wave of digital transformation, and injecting new vitality into the development of the foundry industry.

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On January 4, 2024, the first Science article of 2024 was published by the team of Professor Yang Peidong, a member of three academies in China and the United States and an inorganic chemist at the University of California, Berkeley.

Blue and green emitters with high photoluminescence quantum yields are currently at the forefront of research in solid-state lighting and color displays. Prof. Peidong Yang's team has demonstrated blue and green emitting materials with near-uniform photoluminescence efficiencies through supramolecular assembly of hafnium and zirconium halide octahedral clusters. The highly luminescent halide chalcogenide powders have excellent solution-processability for thin-film displays and self-illuminated 3D printing. The photoluminescent powders were homogeneously dispersed into the resin by stirring and sonication. The blue and green emitters were assembled into complex macroscopic and microscopic structures using a multimaterial digital light printing method. The resin was rapidly transformed into solid 3D structures under 405 nm structural UV light irradiation.

Printed architectural models of the Eiffel Tower show their respective blue and green colors after 254 nm excitation. Both Eiffel Towers are within a few centimeters of each other and feature high-resolution spatial features.A close-up view of the boundary between the blue and green emitting regions within the 3D-printed octet truss structure reveals a high degree of precision in the color transitions, with no color crossover on either side. The octet truss structure with dual emission also achieves bright emission and high structural accuracy.The potential applications for 3D printed light-emitting structures are vast and evolving, ranging from complex lighting solutions for indoor environments to seamless integration into wearable devices.

The second Science 2024 article in the field of 3D printing technology was published on February 8th. A joint team from the University of Queensland, Australia (Jingqi Zhang et al.), Chongqing University (Ziyong Hou, Xiaoxu Huang), and the Technical University of Denmark has achieved in-situ alloying for the 3D printing process by adding Mo to Ti5553 metal powder.

Specifically, by precisely delivering molybdenum into the molten pool, molybdenum can act as a seed nucleus for crystal formation and refinement during each layer scan, facilitating the transition from large columnar crystals to a fine equiaxed and narrow columnar crystal structure. Molybdenum also stabilizes the desired β-phase and inhibits the formation of phase heterogeneity during thermal cycling, by which not only the strength of the 3D printed titanium alloys is improved, but also a perfect balance of ductility and tensile properties is achieved.

While TC4, the so-called workhorse of the titanium industry, has a recommended minimum elongation at break of 101 TP3T, the titanium 5553 prepared by this 3D printing has a great potential for application with a yield strength of 926 MPa and an elongation at break of 261 TP3T. The method is also expected to be applied to other metal powder mixtures and to customize different alloys with enhanced properties.

The first Nature article in the field of 3D printing technology in 2024 was published on February 27th. A team of researchers from the Institute of Metals, Chinese Academy of Sciences (IMS) published an article titled "High fatigue resistance in a titanium alloy via near void-free 3D printing".

The article argues that the underlying 3D printed microstructures have a naturally high fatigue resistance, and that the degradation of this property may be caused by the presence of micropores. Conventional efforts to eliminate micropores often result in tissue coarsening, while the process of tissue re-refinement brings about the recurrence of porosity and even triggers new disadvantages such as the enrichment of α-phase at grain boundaries, making the microstructures dilemma of in-and-out efforts.
During the heat treatment research conducted by the CAS team, a key post-treatment process window was discovered, where the phase transition and grain growth of 3D printed titanium alloys at high temperatures are asynchronous. With sufficient superheat, the α to β phase transition occurs immediately, and although the β phase growth temperature has been reached, the grain boundaries need a gestation period to rearrange themselves. Taking advantage of this valuable heat treatment window, the researchers determined a heat treatment method combining hot isostatic pressing and high-temperature short-time treatment, which both achieved tissue refinement and prevented α-phase enrichment as well as the reappearance of micropores, and ultimately prepared near-printed state 3D printed titanium alloys that are almost free of micropores.

TC4 titanium alloys with this microstructure achieve a high fatigue limit of about 1 GPa, exceeding the fatigue resistance of all current additively manufactured and wrought titanium alloys, as well as other metallic materials.

The 2nd Nature article in the field of 3D printing technology in 2024 was published on March 13th. Building on a continuous liquid interface production technique developed at the university in 2015, researchers at Stanford University have developed a 3D printing technique for more efficient production of microscale particles, making up to 1 million micron-sized particles per day with high precision and customizability.

Nano- to micron-scale particles have a wide range of applications in biomedical devices, drug and vaccine delivery, microfluidics, and energy storage systems. However, conventional fabrication methods require balancing multiple factors such as fabrication speed and scalability with particle shape and uniformity and particle properties.
Researchers at Stanford University have developed a scalable, high-resolution r2r CLIP 3D printing process that uses single-digit micrometer resolution optics with continuous film to enable rapid, variable fabrication and harvesting of particles with a variety of materials and complex geometries. With this technology, researchers can achieve micron-level precision 3D printing while maintaining high production speeds and flexibility in material selection, opening up new possibilities for particle manufacturing.

This scalable particle production technology has been demonstrated toManufacturing potential in a wide range of fields from ceramics to hydrogel manifoldsThe research was published under the title "Roll-to-roll, high-resolution 3D printing of shape-specific particles," and subsequently has potential applications in microtooling, electronics and drug delivery. The study was published under the title "Roll-to-roll, high-resolution 3D printing of shape-specific particles".

Source: AMReference

On March 20, the Long March 8 Remote 3 Launch Vehicle (R3LV) successfully put the Magpie II satellite into the scheduled orbit. The Sixth Academy of Astronautics pointed out in a related report that "during this launch, there wereSatellite storage tank structure realized by 3D printing processThis has laid a good foundation for the mass production of microsatellites and network launching, which has significant commercial value".

On April 3, 2024, the Magpie Bridge conduction technology test satellite for the Moon Exploration Project, Tiandu-2, was separated normally in orbit, and the cold push system worked normally.Marking the first time that domestic spaceflight realizes the application of 3D printed storage tanks in orbit, laying a solid foundation for the use of 3D printing technology in space propulsion.

The tank is jointly developed by Institute 801 of the Sixth Academy of Space Science and Technology and Institute 800 of the Eighth Academy of Space Science and Technology, and is made of aluminum alloy. The research team has realized the integration and lightweight design of the receptacle with subversive technological innovation program, developed high density, high-precision laser selective melting and forming and precise control of post-processing methods, and successively conquered key core technologies such as integrated design technology of the structure and function of the receptacle, densification forming technology of thin-walled structure, and post-processing technology of aluminum alloy internal runner, and so on. Based on the realization of integrated molding, the development cycle of the storage box is shortened by 80% and the cost is reduced by 62%.

this isThe first 3D-printed aluminum alloy storage tank in China to be integrally molded and applied in orbitIn addition to the highly integrated installation of all components on the tank, the tank also realizes the connection between each component through the 3D printed runner, without the need for conduit connection. The development team has fully implemented the digital design concept of "multiple iterations in the digital world and one success in the physical world", adhered to the development mode of "ultimate product improvement", and reached the domestic first-class level in the development of 3D printed storage tanks, and has made great efforts to "catch up with and surpass the world". "We are striving to catch up with and surpass the world's advanced level, and contributing new strength to the aerospace industry.

Source: AMReference

On April 4, 3D Printing Technology Reference noted that a traditional metal injection molding developer called Greene Group Industries (GGI) acquired Holo, a developer of indirect metal 3D printing technology, in an event that is actually of significant landmark significance.One is that "advanced" 3D printing technology has failed to find enough industry applications to support its healthy growth, and the other is that traditional manufacturing industries have recognized the value of 3D printing technology to their production processes.The

Holo isAutodeska spin-off company of the company that developed the light-curing-based PureForm metal indirect 3D printing technology that enablesPure copper, stainless steel, titanium alloy, nickel-based high-temperature alloyRapid prototyping and scale-up production of complex metal parts in materials such as...In particular, it should be noted that the company was the first to tackle pure copper 3D printing based on DLP technology.Through DLP + DegreasingSintering processThe densities of the formed pure copper average 96-98%, which is sufficient to achieve the thermal and electrical conductivity of 95% for bulk copper. Additionally, the process may reduce the cracking problems associated with laser printing. Based on an already proven process, Holo is focusing on the development and manufacturing of heat sink parts rather than selling 3D printers.3D Printing Technology Reference 2021 reports that one of its pilot production lines20,000 pure copper small parts can be produced per monthand hopes to produce millions of copper heatsink parts each year.

With a 100-year history of providing high-quality metal parts, GGI is recognized as an industry leader in a variety of metal forming technologies, including stamping, forming, CNC machining, wire EDM, and metal injection molding (MIM). Its advanced manufacturing, sales, and support network allows it to quickly provide prototypes and develop short-run production processes from initial product concepts.

Holo's technology complements our metal injection molding, stamping and precision machining offerings," said GGI's CEO. This deal allows GGI to deliver prototype metal parts in less than two weeks with surface quality and feature resolution comparable to metal injection molding.PureForm additive manufacturing technology will strengthen our partnership with our customers by supporting faster iterations throughout the product lifecycle., while GGI maintains its superior engineering services and quality."

Holo's flagship PureForm additive manufacturing technology uses a metallic paste made from a blend of MIM powder and light-curing resins to enableDeveloping Indirect 3D Printing of High-Resolution, High-Throughput Parts. Specifically, the technology produces high-precision part blanks based on the principle of photopolymerization from a mixture of metal powder and photosensitive polymers. A mask exposure allows precise and fast molding of the entire layer, and the polymer binder selectively cross-links locally, bonding the metal powder together. The printed blank is degreased and sintered to form a densified part.

Indirect metal 3D printing.end upIntegration with the MIM industry

The back-end process of indirect 3D printing technology is identical to that of MIM technology, making it very easy for traditional metal injection molding manufacturers to incorporate the technology into their production process.

Indirect 3D printing technology helps enable rapid prototyping that is difficult to achieve with traditional manufacturing methodsThis is the type of technologyOne of the key values for the MIM industryGGI's acquisition of Holo is a key reason why 3D printing technology is an important complementary or even disruptive technology for early part development in the MIM field, as it eliminates the need for molds and dies and significantly improves development flexibility, shortens development time, and reduces development costs.

Currently, indirect metal 3D printing technologies such as binder jetting and light curing use powder for MIM as the 3D printing material, which has not increased the material cost for the MIM industry. For indirect metal 3D printing based on light curing, it is possible to achieveUltra-precision 3D printingBetter surface quality and finer detailed features.surpassing evenMIM-standardized parts. On top of that, Holo claims that its technology enablesScale production of complex designsand is considered ideal for aerospace, automotive, medical, electronics and industrial applications.

Source: AMReference

On April 12, the 130-ton reusable liquid-oxygen kerosene engine independently developed by the Sixth Academy of Aerospace Science and Technology Group successfully completed two start-up ground ignition tests. So far, the engine has completed a total of 15 repetitive tests, 30 ignition starts, the cumulative length of the test exceeded 3900 seconds, the number of repetitive tests exceeded the record number of tests of China's main engine of liquid rockets, laying the foundation for the subsequent first flight of China's reusable launch vehicles.

Power comes first in the development of spaceflight. The prerequisite for the development of reusable rockets is to take the lead in developing a successful reusable engine. It is reported that, compared with traditional disposable rockets, reusable rockets will add four key technologies: first, "accurate (landing)", and two."have a good connection", and three."last forever", and four."quick fix". And these key technology breakthroughs, the development of reusable engines bear the brunt. This type of engine as a follow-up to China's reusable launch vehicle main power, with high comprehensive performance, strong expansion capabilities, high reliability and other characteristics.

In terms of design and development, the Sixth Academy's development team adheres to the development concept of "technical limit mapping, extremely fast R&D iteration, and extreme product improvement", and practices the spirit of "must catch up with and exceed the world's advanced level", and has answered the question of how to "land accurately" and "connect steadily" by mastering a number of core key technologies such as multi-ignition, wide-range inlet pressure, start-up, and wide-range variable thrust. By mastering multiple ignition, wide range of inlet pressure, wide range of variable thrust and other core key technologies, the institute has answered the question of how to "land accurately" and "catch steadily"; by breaking through the technologies of fast and simple maintenance and condition inspection and evaluation, the institute has solved the problem of "not broken" and "repaired". Through the breakthrough of fast and simple maintenance and condition inspection and assessment technologies, the problem of "not broken" and "fast repair" has been solved; through in-depth analysis of the mechanism, continuous optimization of the structure, and full implementation of test validation, the weak links of the engine are comprehensively managed, and the inherent reliability of the engine has been continuously improved.

In terms of intelligent manufacturing, the development team of the Sixth Academy has planned and implemented 69 research projects for technological research and improvement based on a flexible and agile unitized manufacturing system and an efficient and integrated digital management and control system, and with the requirements of the key technical indicators of the reusable engine as the traction, the Sixth Academy is now planning and carrying out 69 research projects for technological research and improvement.Breakthrough in additive manufacturing one-piece molding of complex structural assembliesThe company has established a core technology system for the production and manufacturing of reusable engines, and has significantly improved the advanced and stable engine technology, product quality consistency and reliability.

In recent years, with the development of manufacturing industry and technological progress, 3D casting technology is gradually showing its unique application value in various fields. Especially in the field of ultra-large castings manufacturing, the application of 3D casting technology by the domestic and foreign head manufacturers in related fields of concern and favor.

According to the information, Tesla, BMW, BYD and other car companies are already using 3DP sand mold printing technology. Tesla uses 3D sand casting technology to quickly and cost-effectively verify the design and engineering specifications of giant molds. A concept model of Mercedes-Benz uses 3D sand casting to realize the casting of single large-size parts of the rear subframe, suspension bracket and other structures. Domestic BYD new battery company is exploring 3D printing technology in the new energy vehicle prototyping, automotive parts and thermal management systems and other areas of forward-looking application development.

In the aerospace field, 3D sand casting technology can be used to manufacture engine parts, spacecraft structural parts, power units and other important parts. Can effectively solve the oversized, multi-dimensional curved surfaces, complex structure of the workpiece molding problems, in small quantities of large size mold manufacturing as well as special industry mold iterative upgrading research and development on the traditional manufacturing process can not be compared with the advantages. In the field of energy and power, 3D casting technology can be applied to large-size pressure-resistant complex cavity structure, large thin-walled lightweight parts and other manufacturing.

It can be seen that large casting manufacturing has a wide range of application needs in the fields of aerospace, shipping, pumps and valves, automotive (new energy), energy power (electrical), industrial machinery (robots/UAVs), rail transportation, 3C electronics, sculpture, education and research, rehabilitation and medical care, etc., and the traditional manufacturing methods are facing a lot of challenges, especially in the R&D trial stage of new products. For example, due to the huge size of castings, they usually need to be split into parts for casting and then integrated by welding, which not only increases the design burden, time and cost, but also easily leads to welding defects, affecting product quality and consistency. At the same time, modifying the mold is also a challenge.

The 3D casting technology can give a better solution for many characteristics of large castings:

1. Complex structure design optimization. 3D printing technology can manufacture complex shapes and structures that are difficult to achieve with traditional processes, further expanding the design space and providing more innovative possibilities.
2. Lightweight products. 3D printing technology can achieve local optimization of materials and hollow design, so that parts can maintain sufficient strength, but also to reduce weight.
3. Function integration integration. In the automotive industry, 3D printing technology has been heavily used in the integrated design, the same parts to achieve multiple parts, a variety of functions of the integration.
4. Batch customization. Batch customization of large castings using traditional processes to open the mold high cost, long cycle, 3D printing can save time and cost of opening the mold, improve efficiency and cost savings.

In order to meet the market demand for large-scale casting manufacturing, 3D printing equipment and rapid manufacturing service provider Beijing SANDY Technology Co., Ltd. was the first in China to launch a self-developed large size 3DP sand printer 3DTEK-J4000, the device breaks through the traditional processing size limitations, the maximum molding 4 meters of sand. Equipment creatively used without sand box flexible area molding technology, breaking the equipment molding size, the larger the price of the equipment wildly soaring strange phenomenon, making 4 meters or larger size of the equipment, and 2.5 meters of the price difference between the equipment to become possible. Economy, flexibility, with lower unit cost and shorter delivery time, cost-effective realization of oversized sand molding manufacturing, and can be customized according to user needs on-demand expansion of the printing platform to meet the production needs of the 10m + level (6m/8m/10m equipment has been in the synchronization of accepting bookings), to help users maximize productivity. (Foreign friends can click here to learn about our large 3D printer)

The equipment adopts international first-line high-precision, high-throughput nozzle, with high-performance molding process and intelligent algorithm technology, which can provide users with excellent molding accuracy, balanced and controllable casting performance and excellent reliability. Equipped with high-speed vibration type powder spreading system, automatic powder circulation system and self-developed equipment control software, etc., the sand mold has good dimensional accuracy, high strength, low outgassing and excellent surface quality; the equipment is easy to operate, stable and reliable, with printing warning prompts, and the "visual monitoring and intelligent system" can realize real-time monitoring and record traceability of the whole process; the open-source material process can provide users with excellent casting performance with balanced control and excellent reliability. Traceability of records; open-source material technology, can be adjusted according to the user's needs; supporting high-performance resin binder, curing agent, cleaning agent, to ensure the quality and stability of molding.

A user giant, large plane, thin-walled structural components, the use of traditional welding and casting process is difficult to meet the requirements, the use of three emperor technology 3D casting process, 45 days to deliver two finished products, finished product size of 1800mm × 2000mm, wall thickness of 5.5mm.
A customer's giant aluminum alloy casting weighing 1.25 tons, with a diameter of 900mm at the lower end, 1200mm at the upper end, and a height of 1850mm, had high costs and long lead times in traditional manufacturing methods, and was unable to achieve the required complex structure. The delivery was completed in only 15 days by using 3D casting process of SANDI Technology, which saved a lot of time and cost for the customer.
The lightweight, large-surface, thin-walled new energy commercial truck subframe delivered to the customer by SANDI Technology weighs about 27KG, with a wall thickness of 5.5mm, and is made of high-quality aluminum T6061. Traditional casting requires 1-2 months for mold manufacturing alone, and the cost is high. The 3D casting process of SANDI Technology will complete the delivery of finished products in 2 weeks.

[About SANDI TECHNOLOGY
(3D Printing Technology, Inc.) is a 3D printing equipment and rapid manufacturing service provider, national high-tech enterprises, specializing in new enterprises, the Ministry of Industry and Information Technology additive manufacturing typical application scenarios supplier. It is also the innovator of "SLS+SLM+3DP+BJ" 3D printing technology, and its business covers the research and development and production of 3D printing equipments, 3D printing raw materials, rapid manufacturing services for finished metal parts, and technical support services for 3D printing processes, etc. It has established a complete 3D printing rapid manufacturing industry chain, which is widely used in the following areas Aerospace, ships, pumps and valves, automotive (new energy), energy power (electrical), industrial machinery (robots / drones), rail transportation, 3C electronics, sculpture, education and scientific research, rehabilitation and medical care and other industries.

Introduction：Because the 3C consumer electronics field presents an explosive market demand for 3D printing, Apple, Samsung, Huawei, BYD's supplier Kangrui new materials, with revenue of 2.47 billion yuan in 2023, is going to get involved in 3D printing! At the end of last year, a Huawei supplier in Guangzhou enhanced its 3D printing capabilities by acquiring a metal 3D printer manufacturer.

Gu Wenyu, member of the Standing Committee of Jiangyin Municipal Committee, deputy secretary of the CPC Working Committee and deputy director of the Management Committee of Jiangyin High-Tech Zone, said at the signing ceremony that Jiangyin High-Tech Zone has been actively implementing the strategy of innovation drive in recent years, with a focus on supporting the development of high-end equipment industry, especially the 3D printing industry. For enterprises such as Kangrui and SanDi Technology, Hi-Tech Zone will provide all-round support to accelerate project construction and jointly promote the vigorous development of the industry.

Figure: Zhu Wei, Chairman of Jiangsu Kangrui New Material Science and Technology Co., Ltd. introduces the project development (left); Zong Guisheng, Chairman of Beijing SANDI Technology Co., Ltd. introduces the industrial cooperation (right)

SANDI Technology and Kangrui New Material are both active practitioners of new quality productivity.

Over the years, SANDI Technology has been actively promoting the development strategy of "3D Empowerment" and "3D3C" with the vision of "Starting from 3D printing, upgrading manufacturing with digital technology". Under the guidance of this strategy, SANDI has not only realized its own technological innovation and breakthrough, but also empowered many casting and injection molding enterprises, injecting new vitality into the production of 3C products.

With an annual production capacity of over 20,000 tons of precision metal materials, Kangrui New Materials focuses on providing high-precision, high-performance precision metal materials of specific materials and structures for downstream customers in the field of precision manufacturing. The company's products include metal laminated composites (titanium-aluminum composites, steel-aluminum composites, copper-aluminum composites), precision metal profiles, and precision metal polished rods, fine wires, and other multi-morphic precision metal materials, which are used in consumer electronics, automotive parts, industrial equipment parts, medical equipment and other applications.

With its advanced adhesive jet 3D printing technology, SANDY Technology has successfully realized the mass customized production of casting and injection molding, providing a brand new solution for the manufacturing of complex parts, empowering the development of casting and injection molding enterprises, and providing rapid manufacturing services through more than ten subsidiaries distributed in China. At the same time, SANDI Technology utilizes its nearly one hundred patented laser 3D printing technologies to enter the application field of 3D printing in 3C products, obtains the first domestic registration certificate of 3D printing customized titanium alloy hearing aids for medical devices, and quickly cuts into the field of manufacturing through the cooperation of communication terminal parts.

The relevant person in charge said that this cooperation with Kangrui new materials, first of all, to develop and produce 3C special 3D printing equipment, to realize 3D printing intelligent, automated, low-cost mass production of communication terminal parts; and then promoted to other applications, such as new energy vehicles and so on.
Polar Bear 3D Printing
If Apple, Huawei, Samsung, Xiaomi, Glory, OPPO, vivo, these 3C big manufacturers really adopt 3D printing process in large quantities, it is difficult for domestic manufacturers to be able to withstand so many production tasks at present. It may take hundreds or even thousands of metal 3D printers, printing titanium alloy powder up to a thousand tons/year, to meet the delivery of high-volume parts.

Relevant institutions predict that within 2030, the largest application market of 3D printing technology will appear in 3C consumer electronics/automotive and other civilian areas, up to the level of hundreds of billions of dollars, more than the current military defense market, presenting several billions or even tens of billions of dollars of level of the application of the enterprise.