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3D Printing For Sand Casting Patterns PDF

Greycast Founders Pvt. Ltd. faced challenges with traditional sand casting pattern production methods, including high production lead times of 2-4 weeks, high third-party dependency, and higher costs. Divide By Zero provided Greycast with a 3D printer to print sand casting patterns, reducing lead times by 60% and costs by 80% while increasing control, flexibility, and efficiency. Greycast now has an advantage over competitors and is happy with the results from using Divide By Zero's 3D printing solution.

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195 views3 pages

3D Printing For Sand Casting Patterns PDF

Greycast Founders Pvt. Ltd. faced challenges with traditional sand casting pattern production methods, including high production lead times of 2-4 weeks, high third-party dependency, and higher costs. Divide By Zero provided Greycast with a 3D printer to print sand casting patterns, reducing lead times by 60% and costs by 80% while increasing control, flexibility, and efficiency. Greycast now has an advantage over competitors and is happy with the results from using Divide By Zero's 3D printing solution.

Uploaded by

skrgoel
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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3D Printing for Sand Casting Patterns


The application of possibilities of 3D printing is limitless. 3D printing has already
become a routine name in applications such product design, architecture, and
engineering. The transition of this nascent technology in to other verticals
manufacturing and production was only natural. This transition was exemplified in one
of DBZ’s Mumbai-based clients Greycast Founders Pvt. Ltd’s manufacturing process.
Greycast Founders Pvt. Ltd.

Greycast Founders Pvt. Ltd. is a leading company in manufacturing and exporting a wide
variety of metal castings based in Mumbai, India. Its product range comprises of S.S.
Casting, special alloy steel, Ni-hard, haste alloy, heat resistant, high manganese steel
casting to name a few making it the foremost exporters of stainless steel casting in
India.

Conventional Sand Casting Patterns


In the process of designing a cast or casting, a pattern is a mock-up of the object to be
cast. This mockup is used to prepare a cavity in sand followed by pouring of design
molten material to complete the casting process. Conventionally, Patterns used in sand
casting are made of wood or metal. Making pattern out of conventional materials is
expensive, manual, time consuming and requires skilled-labor.

Current Challenges
Just like most manufactures, Greycast Founders had their sand casting patterns
developed in wood or Aluminum. These were developed externally from third-party
craftsmen. The client of Greycast Founders provided only design files or drawings.
Following are some of the key challenges faced by Greycast Founders.

1. High Production Lead Time – Currently, the ideal lead time for developing a
wooden pattern is between 2-4 weeks subject to the complexity of the design.
This high turnaround time in the pattern design process adds and leads to higher
production lead times.

_____________________________________________________________________________________________________
Divide By Zero Technologies
H.O: No. 20, Growmore Tower, Phone: +91-9167943604
Sector – 2, Kharghar, Navi Mumbai – 410210. Email: [email protected]
_____________________________________________________________________________________________________

2. High Third-Party Dependency – The current process of having patterns


developed from third-party partners depended heavily on their availability, skill-
level and willingness to adhere to timelines. It also involved cumbersome manual
follow up and logistics procedures. As Greycast Founder’s client only provided
design files or drawings, the final outcome depended heavily on the skill-set of
the third-party partners.
3. Higher Cost - Fabricating or developing the patterns is often difficult, time-
consuming and expensive. The extremely skilled nature of sand casting patterns
development is subject to erratic price changes by the third-party partners.
Additionally, potential for problems such as design flaws, tolerance variations,
incorrect shrink compensation, IPR infringement and iterations add to the cost
per pattern and overall lead time.
4. Lack of Agility – All the factors mentioned above led to lack of agility and high
external dependencies. Greycast Founders were unable to getting quick orders
from clients due to poor availability of infrastructure for rapid sample pattern
development. Greycast Founder’s also has limited or no visibility during the
actual development of sand casting patterns.

Solution by DBZ
Divide by Zero provided Greycast Founders with our Aion 500 3D printer. They used 3D
Printers to print samples for taking orders from their end clients eventually integrating
it in their actual production scenario.

_____________________________________________________________________________________________________

Divide By Zero Technologies


H.O: No. 20, Growmore Tower, Phone: +91-9167943604
Sector – 2, Kharghar, Navi Mumbai – 410210. Email: [email protected]
_____________________________________________________________________________________________________

Benefits of using Divide by Zero Technologies 3D Printer


After implementing Divide by Zero Technologies 3D
Printers, Greycast Founders were able to harness the Time Cost
following benefits: 26000
24000
 Diminished dependency on third-party 22000
20000
partners 18000
 60% reduction in overall lead time (approx) 16000
14000
 Highly accurate samples with a low and 12000
10000
acceptable of tolerance of ±80 microns 8000
6000
 80% reduction in overall cost (approx) 4000
 Added agility thanks to rapid 3D printed 2000
0
sample pattern development TRADITIONAL 3D PRINTING
METHOD
 Increased operational efficiency
 Faster design revisions
 Seamless integration with various designing and modeling applications
(software)
 Full visibility and control during actual development of sand casting patterns

Customer Testimonial:

“Reduction in Cost and Time has given us a


Competitive advantage. We are very happy to use
Divide by Zero Technologies 3D Printers”

_____________________________________________________________________________________________________
Divide By Zero Technologies
H.O: No. 20, Growmore Tower, Phone: +91-9167943604
Sector – 2, Kharghar, Navi Mumbai – 410210. Email: [email protected]

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