The ExOne — Flex Webinar (May 2022)
26 slides from The ExOne's conference presentation, May 25, 2022
Slide 1: How Sand 3D Printing Is Reviving Foundries
HOW SAND 3D PRINTING IS REVIVING FOUNDRIES BEN LEUNG BEN.LEUNG@EXONE.COM VICE PRESIDENT, ASIA PACIFIC 25.05.2022
Slide 2: About ExOne
About ExOne Part of the Desktop Metal family since 2021, ExOne is the pioneer in sand binder jet 3D printing. Since 1995, we’ve delivered powerful 3D printers that help foundries survive and thrive with more efficient and innovative production technology. © 2022 The ExOne Company 2
Slide 3: Established in the Industry | 20 Years of Sand 3D Printing
Established in the Industry | 20 Years of Sand 3D Printing 200+ ExOne printers installed in foundries around the world. Learn more at exone.com/sandsuccess Humtown Hoosier Pattern Kimura Foundry America Xylem Eisengiesserei Mezger Third-generation family- First pattern shop in North Prototype
Slide 4: Sand 3D Printing | Transformational Benefits
Sand 3D Printing | Transformational Benefits Faster delivery times, done-in-one pours, and new design freedoms OEMs and foundries optimize business with binder jetting to deliver castings with EXCEPTIONAL complex designs and fast turnarounds, while RAPID saving money on patterns, molds, and labor. D
Slide 5: Binder Jetting | Process Overview
Binder Jetting | Process Overview Liquid binder applied to powder to form parts and tooling Digital File Machine & Prep Material Prep 3D Printing Sand molds & cores Depowder Cure optional Next steps depend on material and application Sand tooling Depowder Coat or infiltrate Metal & ceramics Cure Dep
Slide 6: The Economics of Sand 3D Printing
THE ECONOMICS OF SAND 3D PRINTING © 2022 The ExOne Company 6
Slide 7: True Cost of Traditional Foundry Technology
True Cost of Traditional Foundry Technology Beyond cost per cubic inch Factors to consider when evaluating 3D printing and other processes affected where cost savings may occur: Traditional tooling (lead time & iterations) Consumables (resin, media, activator, cleaner) Assembly labor Downstr
Slide 8: When is Sand 3D Printing a Fit?
When is Sand 3D Printing a Fit? From rapid prototyping to production volume castings without conventional tooling Sand 3D printing is another tool in the foundry toolbox. Taking advantage of digital manufacturing makes sense for: Quick-turn, tooling-less castings Low volume / small batch product
Slide 9: Mold Production
Mold Production Design freedom to create complex mold rigging When time is of the essence, complete mold packages can be 3D printed without traditional tooling. Done-in-one pours are also enabled with the design freedoms that provide the ability to throttle the velocity of the pour and achieve the o
Slide 10: Core Production
Core Production Complex designs that lead to core consolidation When expensive tooling is required, 3D printing is advantageous for low quantity production. For highly complex parts, sand 3D printing may be cost effective, even if tooling exists or for high quantity production, especially in situati
Slide 11: Hybrid approach combining 3D printed cores with conventional sand molds
For many applications, a hybrid approach is often the most practical, combining complex 3D printed cores with conventional sand molds © 2022 The ExOne Company 11
Slide 12: Beyond 3D Printing | OneCast Sandcasting Solutions
Beyond 3D Printing | OneCast Sandcasting Solutions Full 360° support from combined binder jet and metalcasting experts VIRTUAL CASTING WITH SOLIDIFICATION MODELING VIRTUAL CASTING OPTIMIZE FROM CAD MODELING TO CAST Simulate solidification to determine hot spots Calculate rigging system component
Slide 13: Efficient Operation
Efficient Operation Do more, even without hard-to-find labor Digital manufacturing enables foundries to operate more efficiently, despite We’re able to do more with the people that we have labor shortages Print complete job boxes in 12 Jeff Burek, Vice President hours D.W. Clark Lights-out cor
Slide 14: Labor Attraction
Labor Attraction Engaging a new generation of workers familiar with the digital age The next generation of foundry talent is attracted to modern manufacturing that enables working smarter, not harder Design optimization Digital manufacturing Lights-out production Automation and robotics
Slide 15: Sand 3D Printing Solutions
SAND 3D PRINTING ENTER CHAPTER TITEL SOLUTIONS
Slide 16: Sand 3D Printing | Scalable Foundry Solutions
Sand 3D Printing | Scalable Foundry Solutions Binder jetting for sand molds, cores and new tooling options S-Max® Flex S-Print® S-Max® S-Max® Pro ENTER CHAPTER TITEL User-friendly and affordable robotic sand A fast, flexible, reliable and compact A large and robust sand 3D printer known Our fastest
Slide 17: ExOne | S-Max Flex
ExOne | S-Max® Flex All-new patent- pending robotic The most affordable sand 3D printer sand 3D printer Flexible, scalable ever offered by ExOne for a fast payback developed for footprint for easy ease of use integration Industrial robot arm with innovative printhead end effector binder jets into
Slide 18: 3D Printing System Turnkey Configuration
3D printing system A B c D E F G H \ J K ih M Industrial robot Single Pass Jetting printhead Telescoping build box Build station Cleaning station Fluids cabinet Robot controller Printer operator station Bulk sand conditioning hopper Depowdering station Depowdering bins Ancillary operation station Sa
Slide 19: S-Max Flex | All-New Printhead Design
S-Max® Flex | All-New Printhead Design Easy operation and maintenance with fast print speeds Single-Pass Jetting (SPJ) strategy with three actions each directional pass for fast throughput: • Drop – sand drops from the depositor trough • Spread – sand is spread flat across the build table • Print
Slide 20: S-Max Flex | Automated Telescoping Job Box & Desanding
S-Max® Flex | Automated Telescoping Job Box & Desanding Unique design works similar to a collapsing drink cup Print builds layer-by-layer as sides automatically lift with the job • Contains powder to prevent spills and protect integrity of the build Finished job box slides to the desanding stati
Slide 21: S-Max Flex | 3D Printing Foundry Sand
S-Max® Flex | 3D Printing Foundry Sand Seamless integration into existing foundry operations Dry-mixture of sand plus dry activator • Source your own silica sand Room temperature cure No post processing required Unbound sand is recyclable back into future builds to keep part costs down 3-6
Slide 22: Binder Jetting | Exceeding Customer Expectations
Binder Jetting | Exceeding Customer Expectations Accessible 3D printing enables precision core delivery for components with complex interior geometries INDUSTRY Energy APPLICATION Vapor recovery fuel nozzle LOCATION Alpha Foundry Wright City, MO CHALLENGE Intricate component required six individual
Slide 23: X1 Tooling Portfolio
X1 Tooling Portfolio Rapid tooling printed in sand for the production of metal, plastic, and composite parts X1 SandCast X1 ThermoForm X1 Layup X1 Washout Sand 3D printing quickly and On-demand tooling for Whether low-cost prototyping or Eliminate the expense, lead time, accurately produces complex
Slide 24: TeamDM | We Turn Powder into Parts
TeamDM | We Turn Powder into Parts Binder jetting a wide range of powder materials POWDER MATERIALS WE PROCESS SAND METAL CERAMICS COMPOSITES Industrial Sands Ultra-fine metal Wide variety of Industrial-grade for metal casting MIM powders ceramic powders composites EX: Silica sand, EX: 316L, 304L, E
Slide 25: Print, Pour, Produce | Questions?
Print, Pour, Produce | Questions? “Every part is always right. Quality remains “500% revenue high across the entire production run, increase in the five including years down the road when you years after investing have to make the part again and just start in ExOne sand with the digital file.” binde
Slide 26: Q&A
Q&A 25.05.2022 | 26