Direct Molding Process

Complex form castings in an ultra short lead time, by utilizing 3D printers to directly create sand molds.

3D sand molding is one of the fastest technologies in additive manufacturing.
By using a 3D printed sand mold, we are able to produce high quality prototype casting without wooden patterns or metal molds.
This efficient process makes us capable of providing high quality small lot castings in an ultra short lead time.

Casting Materials

Cast iron

JIS FC
JIS FCD
JIS FCV

Used in various fields and applications, cast iron is a standard material.
with our extensive experience, we are capable of producing complex forms in a wide size range.

Dimensional accuracy: CT7-9

Heat-resistant cast iron

JIS FCDA
SiMo FCD
SiMoCr FCD

A ductile iron with alloy elements, which is optimized for use under high temperature.
For applications such as turbine housings parts in the automotive industry.

Dimensional accuracy: CT7-9

Cast steel

JIS SC

Used for parts which require higher mechanical properties than cast iron.
Performance can be adjusted by the material compositions and thermal treatment.
Used in applications such as prototype parts for construction machines

Dimensional accuracy CT8-10

Heat-resistant cast steel

JIS SCH

A material made for high temperature applications by adding a large amount of alloy elements.
Used in applications such as prototype turbine housings in the automotive field/industry.

Dimensional accuracy CT7-9

Stainless cast steel

JIS SCS

A material used for parts which require corrosion resistance.
Used in applications such as stainless-steel impellers.

Dimensional accuracy CT8-10

2017 DMP Production Volumes

Delivery Process

Two types of sand molds: comparing Furan resin and phenol

1. Furan process: A process of applying self-hardening furan to additive manufacturing
This process has advantages such as precise dimensional accuracy and efficient production.

2. Phenol process: High-strength sand molds can be made with thermal treatment after printing.
These sand molds offer the same performance level as shell molds, which makes us capable of difficult applications such as prototypes of hydraulic control valves and bearing housings.

3D Sand Mold Printers

Advanced Process Technology Center

S-MAX

Process	Furan
Max work size	1800mm×1000mm×700mm
Sand type	Mullite-type artificial sand
Sand particle diameter	120μm
Layer Pitch	0.24mm
Printing speed	21 mm/h 38 L/h

S-MAX

Process	Furan
Max work size	1800mm×1000mm×700mm
Sand type	Mullite-type artificial sand
Sand particle diameter	120μm
Layer Pitch	0.24mm
Printing speed	30 mm/h 54 L/h

S-MAX＋

Process	Phenol
Max work size	1800mm×1000mm×598mm
Sand type	Mullite-type artificial sand
Sand particle diameter	120μm
Layer Pitch	0.24mm
Printing speed	18 mm/h 32 L/h

Gunma Plant

S-15

Process	Furan
Max work size	1500mm×750mm×700mm
Sand type	Mullite-type artificial sand
Sand particle diameter	120μm
Layer Pitch	0.24mm
Printing speed	14 mm/h

	Advanced Process Technology Center			Gunma Plant
	S-MAX	S-MAX	S-MAX＋	S-15

Process	Furan	Furan	Phenol	Furan
Max work size	1800mm×1000mm×700mm	1800mm×1000mm×700mm	1800mm×1000mm×598mm	1500mm×750mm×700mm
Sand type	Mullite-type artificial sand	Mullite-type artificial sand	Mullite-type artificial sand	Mullite-type artificial sand
Sand particle diameter	120μm	120μm	120μm	120μm
Layer Pitch	0.24mm	0.24mm	0.24mm	0.24mm
Printing speed	21 mm/h 38 L/h	30 mm/h 54 L/h	18 mm/h 32 L/h	14 mm/h

Technology to address veining defects through the use of artificial aggregates for casting purposes

3D printed sand molds would crack from high temperatures and weren’t suited for casting iron/steel.
We developed an artificial sand, which is durable for casting iron/steel, and also gives a nice smooth casting surface.