+49 2173 101399-0 info@innocast.de

Innovative Production Technologies

innoCast stands for innovative manufacturing technologies. The portfolio includes additive processes such as 3D printing but also classic casting processes. High-performance machining centers complement the wide-ranging portfolio. By combining additive manufacturing technologies with conventional CNC machines, innoCast realizes individual and demand-oriented process chains.

Suitable Material Solutions

Depending on the intended use, mechanical and chemical requirements, we advise you on suitable materials. Thanks to many years of experience in dealing with the sometimes only slightly differing analyses of a material, innoCast always offers the right material solution. And that at optimized cost and quality.

The properties of castings and their quality are decisively influenced by the choice of suitable materials. innoCast specializes in high-strength, heat-resistant steel and iron alloys (e.g. duplex) as well as alloys based on aluminum and bronze. More than 300 materials are available, some of them from our own development.

innoCast Casting Process

Sand Casting

Sand molding or sand casting is a casting process for metal parts made of steel, iron and non-ferrous alloys. It works on the principle of lost mold, which means that the mold is destroyed after being used once to release the cast body.

By using sandprint technologies (tool-less production by 3D printing), sand casting is also suitable for rapid prototyping and small series production of complex components, starting from wall thicknesses of about 3mm. For the production of medium and large series, molds are milled. Sand casting offers great design freedom, therefore versatile shapes and complicated geometries can be realized in technically demanding casting quality.

Investment Casting

Investment casting is used for the production of small to very small castings using the lost wax process. The castings are characterized by detail, dimensional and surface quality. Often, machining can be dispensed with. The lost wax model is produced either from specially suitable waxes by injection molding or by using print or laser technologies. Here, burn-out plastic models (PMMA or PS) are printed directly from 3D data.

The mold itself is created from a ceramic mass. Depending on the size, the wax model is dipped several times in ceramic mass and dried. The resulting shell is melted out and fired in a kiln. After rapid solidification, the ceramic shell is knocked off to expose the cast casting.

Sand Casting

Sand molding or sand casting is a casting process for metal parts made of steel, iron and non-ferrous alloys. It works on the principle of lost mold, which means that the mold is destroyed after being used once to release the cast body.

By using sandprint technologies (tool-less production by 3D printing), sand casting is also suitable for rapid prototyping and small series production of complex components, starting from wall thicknesses of about 3mm. For the production of medium and large series, molds are milled. Sand casting offers great design freedom, therefore versatile shapes and complicated geometries can be realized in technically demanding casting quality.

Investment Casting

Investment casting is used for the production of small to very small castings using the lost wax process. The castings are characterized by detail, dimensional and surface quality. Often, machining can be dispensed with. The lost wax model is produced either from specially suitable waxes by injection molding or by using print or laser technologies. Here, burn-out plastic models (PMMA or PS) are printed directly from 3D data.

The mold itself is created from a ceramic mass. Depending on the size, the wax model is dipped several times in ceramic mass and dried. The resulting shell is melted out and fired in a kiln. After rapid solidification, the ceramic shell is knocked off to expose the cast casting.

3D printing for investment and sand casting

3D Printer Sand Molds and Melt Out Models

At innoCast, various rapid prototyping processes are used. Here, either sand molds or melt-out models made of PMMA (thermoplastic) are printed directly from 3d data. Modern Voxeljet 3D printers are used, which are mainly used for the tool-free and fully automated production of high-quality models and print cores. The machines achieve very high accuracy at an equally high build speed.

3D cast-out models are used as lost models to build the ceramic shells used in investment casting. These are built up in layers by the 3D printer. For sand casting, the molds and cores for the mold boxes are created in the 3D printer.

For both investment and sand casting, the production time is greatly reduced by the tool-less process, as process steps such as tooling are eliminated. Depending on the complexity, we achieve a lead time of approx. 10 days to the raw casting and approx. 15 working days with finishing.

3D Printer Sand Molds and Melt Out Models

At innoCast, various rapid prototyping processes are used. Here, either sand molds or melt-out models made of PMMA (thermoplastic) are printed directly from 3d data. Modern Voxeljet 3D printers are used, which are mainly used for the tool-free and fully automated production of high-quality models and print cores. The machines achieve very high accuracy at an equally high build speed.

3D cast-out models are used as lost models to build the ceramic shells used in investment casting. These are built up in layers by the 3D printer. For sand casting, the molds and cores for the mold boxes are created in the 3D printer.

For both investment and sand casting, the production time is greatly reduced by the tool-less process, as process steps such as tooling are eliminated. Depending on the complexity, we achieve a lead time of approx. 10 days to the raw casting and approx. 15 working days with finishing.

Casting Process Simulation

 

At innoCast, the casting process is designed and optimized with the aid of simulation software. Here, the filling and solidification behavior is analyzed. The casting technology can be optimized and adapted in advance.

Through simulation, the quality of a casting can be precisely described before production begins and the casting technique can be aligned with the desired part properties. This not only eliminates expensive test castings during development. The precise design of the entire casting system also saves energy, materials and tooling costs. As a result, time and costs can be consistently saved throughout the entire production chain.

Mechanical Finishing

The final manufacturing stages of any project are crucial for the proper functioning and quality of the product. The mechanical finishing of castings is optimally integrated into the manufacturing process. innoCast machines parts from its own production as well as on customer order. In addition, components made of metal materials are also produced according to drawings and CAD data.

All common interfaces are available for data transfer.

innoCast has state-of-the-art 5-axis machining centers of the latest generation as well as CNC-controlled turning-milling centers. Cast and metal parts can be machined and produced around the clock on request.

CONTACT US

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ABOUT US

Learn more about the innoCast group of companies and its associated subsidiaries.

CONTACT BY PHONE

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+49 2173 101399-0