Rapid Casting

Speed is not magic, but rather a question of organisation and the availability of the right technology. In addition to conventional manufacturing processes, Brechmann-Guss offers the possibility of reducing the usual delivery times for new parts from around 10 weeks to 10 working days, particularly for development, prototypes and, if necessary, small series.

10 weeks

10 days

The global market reduces the time available for projects

Today´s global market is forcing many customers to adopt ever shorter product development cycles while increasing the number of variants; Often, the design of a casting is omitted because it is easier to quickly “weld together” a few sheets of metal and “readjust” them in the field than to design a clean model, build a model and, if necessary, core boxes, create test castings and then venture into field testing. “Rapid casting” – as a process and procedure description – at least without the use of core boxes, offers a real alternative using 3D-printed cores (and moulds, if necessary).

3-6 Prototypes / spare parts

3D printing is a generative manufacturing process in which the 3D data set (of the core or mould) is “broken down” into thin layers. A layer of quartz sand with a binding agent is applied to a carrier plate and the layer geometry of the first layer is selectively bonded and thus firmly connected. The carrier plate is lowered, the next layer of sand is applied, the next layer is bonded, and so on. Depending on the size of the component (and utilisation of the carrier plate), a geometry ready for casting is available after a few hours – to produce exactly 1 cast part per 3D print. This ratio also characterises the limitation of the process to usually 3-6 castings as a pure prototype/small series process.

Rapid tooling technologies offer an alternative, with a focus on 20–30 castings, where the switch to series tools can be made later. The cost increase for this process is not proportional to the number of units. Contact us to define the right process for your application.

3D print cores are multitasking talents

The advantages of both options are particularly evident in pumps, exhaust manifolds and turbochargers. After design, the external geometry (also determined by screw attachment points and geometric situation) is fixed. However, the detailing of the flow space, which is crucial for the performance of the component, is often only finalised after time-consuming test runs. With 3D-printed cores, an external model can be used to create different internal geometries in a single production
batch, machine them and test the various alternatives simultaneously. The customer saves on various development loops, does not waste money on core boxes that will never be needed again and still has a proven technical solution available at a much earlier stage.

Conversion of 3D data sets into conventional core boxes

Another option for 3D-printed cores is the representation of complex contours that are difficult or – in the case of negative draft angles – impossible to represent using conventional methods. This is because draft angles are not necessary when printing… And this is precisely where the difference between Brechmann-Guss and a pure prototype supplier lies. We also design the print contours in such a way that the 3D data set can be directly converted into a conventional core box when series production starts. Our 3D prints represent the series condition of the component – the data basis is identical.

But regardless of whether it`s grey cast iron or ductile cast iron, ADI or Ni-Resist, our goal is to make the “urgently needed” castings available to the customer as early as possible.