Fully automated 3D printing in the automotive industry

Additive series production continues to make progress: Together with its Spanish partner Loramendi, Friedberg-based voxeljet AG has developed a process for the automatic large-scale inorganic production of sand cores for light metal casting for the BMW plant in Landshut and implemented the system to go with it. The production line with 3D printers and fully automated unpacking solutions as well as microwaves for curing the cores offers a customised solution for the car manufacturer.

3D printing for the production of water jacket cores can significantly improve the design of the cylinder head for the BMW B48 engine. The inorganic process protects the environment and improves working conditions, as only water vapour is produced during casting. At the same time, the efficiency and consumption of the engine can be optimised through the complex design of the cores. No other technology makes it possible to produce such a complex element so (cost-)efficiently in series, reports voxeljet.

Manual processes superfluous

Instead of using individual parts, the car manufacturer can now produce the core entirely using 3D printing. The ICP (Industrialization of Core Printing) production line completely automates the previously manual and laborious process. Five voxeljet 3D printers produce thousands of cores a week using the binder jetting process. These are then unpacked, hardened, cleaned and prepared for casting in Loramendi-developed unpacking stations, microwaves and cleaning cells.

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In our vision, the fully automated production line is the standard we want to achieve: For four years we have worked together creatively, courageously, innovatively and sustainably. The ICP project is a milestone for us and for the automotive industry.

Dr. Ingo Ederer, voxeljet founder and CEO

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The VX1300-X 3D printer is designed for additive mass production and enables bidirectional coating and simultaneous printing of the build area, even in multi-shift operation and continuous use. A fully automated post-processing cell prepares the complex sand cores for metal casting and integrates them into the existing casting process. The toolless assembly of the sand cores enables fast variant changes without stopping production.

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