ExOne Technology 3D Sand Printing

Asia | The Americas | Europe

Company & Technology Overview

David Stevenson

Product Manager


Company Introduction and Global locations

ExOne 3D printing Technology (incl. short video)

Equipment Overview

Production Service Center

Industries, Applications and Customers

Case Studies

Agenda

Asia | The Americas | Europe 3

Company Introduction

and Global locations


ExOne Digital Part Materialization

History / Ownership

ExOne founded by Lawrence Rhoades in 2005 when the finishing

technologies of Extrude Hone were sold to Kennametal, Inc. and

the remaining advanced manufacturing processes were formed

into a new company.

S. Kent Rockwell of Rockwell Venture Capital (formerly of

Rockwell International) acquired ExOne in 2008.

Over $80 million in investment in global research & development

over the last decade.

The ExOne company


• Digital Part Materialization (Additive Manufacturing)

– Sand Printing for Patternless Production of Sand Molds & Cores

– Metal Printing for Functional Metal Parts

– Glass Printing for Glass Components

• Micromachining with Short-Pulse Laser Technology

– Short-pulse laser micromachining for small, complex holes

• Services and Equipment Provided for all Technologies

The ExOne company


Global Facility Locations

160 employees


3D Printing Technology


Digital Part Materialization

Industry-Proven Technology

CAD data Digital cores

CAD data to Digital Part Materialization layer by layer

Cost saving: eliminate tooling

Improve product quality: design freedom

Short lead time: Rapid casting process


Binder systems


Equipment Overview


S-Print S-15 S-Max S-Print 2012

750x380x400 mm 1500x750x700 mm 1800x1000x700 mm 800x500x400 mm

Max 10 liters/hours Max 29 liters/hours Max 108 liters/hours Max 28 liters/hours

Rapid Prototyping Small production Medium production Medium production

High flexibility

Overview

out of production


Build size: 1800x1000x700mm

Speed: up to 108 Liters/hours

Branch: medium production batches

Features:

• Sand recycling;

• Fluidmatic central fluid supply;

• Jobmatic automatic job starter;

• Joblist feature;

• Larger printhead;

• Multisand: silica sand, aluminoxyd, zircon, synthetic sand;

Post-processing: None

S-Max (Furan)


Build size: 800x500x400mm

Speed: up to 28 Liters/hours

Features:

• Sand recycling;

• Joblist feature;

• Larger printhead;

• Multisand: silica sand, aluminoxyd, zircon, synthetic sand;

Post processing (Phenolic and Silicate versions):

Load jobbox into oven using the roller coveyer:

Cure in Microwave oven

Cooling down of jobbox

Extraction and Cleaning of parts

S-Print (Furan – Phenol – Silicate)


Industry – Machine Sales

Industry Machine Count

S15 S-Max S-Print Grand Total

Aerospace 6 4 1 11

Automotive 8 3 3 14

Engineering 2 1 3

Foundry 3 8 2 13

Marine 1 1

R&D 1 1 2 4

PSC 12 7 5 24

Grand Total 33 24 13 70

S15 S-Max S-Print S-Print 2012


Commercial Use

Installations

University/Research

Installations

Machine Locations

Germany: 24 UK: 4

France: 2

Italy: 1

Japan: 10 Kazakhstan: 1

Russia: 9

USA: 14

Canada: 1

Thailand: 1

China: 1

India: 1

Switzerland: 1


Remote Machine Assist


Production Service Center


Production Service Center (PSC)

PSC facilities print digital cores and molds for foundries,

manufactures and engineering companies

ExOne has PSC facilities in Germany, Japan, Russia, America

and Britian

It is planned to open up new PCS facilities in Scandinavia, Italy,

Spain & Portugal, Brazil, China and India

Cores are printed with a high resolution directly from the CAD

data files

Ideal for complex geometries where conventional methods are

difficult

Reverse Engineering of obsolete parts is also possible

CAD Core Cast



Typical S-Max layout


PSC - Digital Core Example


PSC - References Customers


Industries,

Applications and

Customers


Industries - Market Capabilities

Aerospace

Energy/Oil/Gas/Pump

Automotive

Reverse Engineering

Hydraulic systems

Faucets industries

Marine

Institute

Foundries


Gear housing

Decrease lead time by more than 10 weeks

High complexity of cores (reduced number of core)

40% cost saving

Excellent material properties

Applications - Aerospace

Magnesium castings


Pump impeller prototype

Reduce Impeller Prototypes Costs

up to 90%

Decrease lead time by more than

4 weeks

Applications - Energy/Oil/Gas/Pump

Housing and impeller castings


Applications - Automotive

Powertrain castings

FORD 4-cylinder engine block

Aluminium engine block with

cast-in liners

30 blocks casted in 3 months

Decrease lead time by more

than 6 weeks


Applications - Reverse Engineering

Examples

Submarine replacement parts

Reverse Engineer Compressor

Pump Castings with 43 weeks

reduction in lead time

40% cost saving


Customers - Installations


Case Studies


Case Study

Automotive Industry


Benefit

Easier design of mold package (no tool needed)

excellent design freedom

Engineering and CAD Design

Digital Core Production at Danielson


ExOne Technology

3D Sand Printing

Benefit

Molds and Cores with complex geometry available without tooling

cost saving due continous product design modifications


Benefit

Faster assembly and high precision of the cores

Reduce number of cores as freedom in core design

Assembly

Digital Molds and Cores ready for Casting


Benefits

Molds and cores are ready in hours

Industrial proven casting materials (aluminium, magnesium, cast-iron…)

Foundry

Casting with Digital Molds and Cores


Benefits

Short lead time in product development

Complex parts feasible: Innovative product design

Cost saving with design changes (no tooling)

Case study of MCE-5 VCRi


Case Study

Aerospace Industry


• Put the foundry in the 21st Century

Implement digital core production technology

• Create a new economic model

Attract new market and customers

• Develop a process using digital tools

Propose innovative design with the introduction of new materials

Why Digital Core Production

at Fonderie Messier?


• Using sand molds and cores without tooling

High cost reduction

• Reduction of casting development cycle

Reduce lead time for prototypes with digital molds and cores

Systematic usage of digital core for serial production

• Substitute old core box tooling with digital core production

Print directly from CAD data

Digital Core Production

Advantages at Fonderie Messier?


ExOneTechnology

3D Sand Printing

Benefit

Molds and cores with complex geometry available without tooling

Economic and optimised product design modifications


Benefit

Molds and cores are ready in hours

Faster assembly and high precision of the cores

Reduced number of cores through freedom in core design

Assembly

Digital Molds and Cores ready for Casting


Benefits

Short lead time in product development

Complex parts feasible: innovative product design

Cost saving with design changes (no tooling)

Case study of Door hinge

Thank you for your attention [email protected]

Consult with our Experts. Invest in an ExOne system or simply have ExOne manufacture a part for you.

ExOne The Americas

MID-ATLANTIC

127 Industry Boulevard

Irwin, PA 15642

USA

+1 877 773 9663

MIDWEST

2341 Alger Drive

Troy, MI 48083

USA

+1 248 740 1580

SOUTH

7409 Railhead Lane

Houston, TX 77086

USA

+1 281 931 0011

ExOne Europe

ExOne GmbH

Am Mittleren Moos 41

86167 Augsburg

Germany

+49 (0) 821 7476 0

ExOne Asia

161-5 Haneo

Odawara-shi, Kanagawa

Japan 256-0804

+81 465 44 1303

www.ExOne.com

ExOne Technology 3D Sand Printing

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