Alpha Foundry’s in-house ExOne S-Max 3D Sand Printer advances mold and core production with high-precision, speed, and design integrity. Our advanced technology exceeds in producing highly intricate designs, undercuts, and internal passages without the issues of traditional tooling constraints.

Time and accuracy. The ExOne™ 3D sand printing process is super-efficient, with most projects taking no more than a few hours to complete. This alone opens the door to more prototype and small batch projects. We cast aluminum, grey and ductile iron, and ZA12 alloys in both 3D sand for small quantities as well as production volumes with our Alpha Process shell sand molding process. We can even produce hybrid castings using 3D printed cores for complex internal geometry with Alpha Process production molds.

3D Sand Printing allows for real casting production immediately, without the need to wait on tooling/pattern development. It also allows for complex geometry, fewer cores with less variation due to core assembly, and general casting designs that would be nearly impossible with hard tooling and real-world pattern limitations.

We call cleaning 3D sand prints “depowdering.”   Depowdering can become an unnecessarily time-consuming, labor intensive and costly manual activity that creates a bottleneck compared to the speed of the core printing process.  The fastest, most efficient and careful way to clean 3D printed sandcastings is with ShotShower™.  ShotShower™ can not only reduce labor costs but increases quality and lowers scrap rates…and frees up employees for productive work elsewhere in your operations.  See hotideasllc.com to learn more.