In the ever-evolving landscape of manufacturing, CINFU, a leading training center in Portugal specializing in industrial skills and industry-specific training for the foundry industry. Furthermore, CINFU also supports businesses with cutting-edge manufacturing solutions. One of the most impactful integrations in recent years has been additive manufacturing for sand casting applications. This adoption not only enhances their training programs but also provides invaluable support to foundries seeking innovative solutions, fast prototypes or manufacturing solutions for highly complex parts.
The CINFU Advantage
In 2024, CINFU acquired a VX1000 from voxeljet, which proved to be a valuable addition to the services CINFU provides. João Barbosa, a Trainer and Technician Specialist at CINFU, shares their experience, highlighting how it’s reshaping their approach to core production in sand casting.
CINFU isn’t just another training center. It’s a hub of innovation offering customized training and on demand services for foundries across in a variety of fields: CNC machining, CAD/CAM/CAE, and additive manufacturing. Especially as a training center, it is important to stay on top of the industry’s technological advancements. As early as the late 1990s, CINFU started to adopt additive manufacturing, starting with Selective Laser Sintering. “Our initial assessment of 3D printing was focused on its ability to produce complex parts,” Barbosa explains. “This potential was quickly confirmed after our first experiences, motivating us to integrate it into our ongoing training programs and service offerings.”
Embracing voxeljet Technology
In 2024, CINFU expanded their additive manufacturing capabilities with a sand 3D printer from voxeljet. The decision to acquire the voxeljet VX1000 system was driven by two primary factors: the need to train students and professionals in cutting-edge technologies and the desire to support industries with advanced mold and core production capabilities. The VX1000 ODB, which uses the binder jetting technology processing silica sand and furane binder, has proven to be a perfect fit for CINFU’s sand casting processes, taking mold design to a next level.
Transforming Core Production
Traditionally, producing cores for sand casting requires the fabrication of complex tools and core boxes. A process that demands highly skilled foundry mold makers and significant time investments dependent from the part’s complexity. Creating a tool which can be molded can take up to 12 weeks and often requires a compromise between mold or core design and performance of the part, as it is not possible to create highly complex shapes and geometries, due to e.g. undercuts or draft angles. voxeljets VX1000 has revolutionized this aspect of their operations. “With the VX1000, we can print multiple cores in a single build, potentially saving weeks compared to conventional methods. Also, we are not bound by geometric restrictions, as the layer based manufacturing enables us to create even the most complex shapes.” Barbosa notes.
Advantages over traditional methods
Time Savings:
The ability to print multiple parts simultaneously drastically reduces production time, especially for low-volume series.
Cost-Effectiveness:
For small to medium batch sizes, 3D printed printing becomes cost efficient than traditional mold manufacturing, as no tooling is required.
Complexity without compromise:
Additive manufacturing allows for the creation of intricate structures that would be challenging or impossible to create with conventional techniques.
Flexibility:
Prototyping and design iterations can be realized rapidly, enabling CINFU to respond quickly to changing industry or customer demands.
Challenges and Future Outlook
While the benefits are clear, Barbosa acknowledges that there also lie challenges ahead. “Our biggest hurdle will be attracting customers and educating them about the possibilities this technology offers,” he says. Additionally, only partial material recycling (30/70 ratio) remains a weakness of the process, as the mechanical strength of the parts decreases when the ratio is not fullfilled. However, these challenges will also be overcome and CINFU sees a bright future for additive manufacturing in their operations. “As technology and our know-how advances, we anticipate 3D printing will become increasingly relevant, especially in areas requiring intricate, customized parts,” Barbosa predicts.
A New Era for Sand Casting
CINFU’s adoption of voxeljet’s 3D printing technology for sand casting is a prime example of how traditional industries can be revolutionized through innovative approaches. By combining the precision and flexibility of 3D printing with the established benefits of sand casting, CINFU is not just training the next generation of foundrymen and engineers – there are shaping the future of manufacturing. As industries continue to seek faster, more efficient, and more customizable production methods, CINFU’s experience with voxeljets VX1000 ODB system serves as a compelling solution for the potential of 3D printing to support the traditional and beautiful manufacturing process of metal casting.
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