Reduce cost and time by 50% for reusable patterns of any complexity and size.
Up to 50%
cost reduction over conventional patterns
2x
faster pattern production
50x50x72"
(1270x1270x1828mm) single-piece patterns

Accelerate Casting Production with 3D Printed Patterns

The sand casting process is evolving thanks to the benefits and advantages offered by Additive Manufacturing (AM). By incorporating AM into your process, you can achieve faster, more cost efficient and more agile production of patterns and core boxes.

With 3D Systems additive manufacturing solutions and expertise, you can reduce production time for medium to large casting patterns from weeks to days without sacrificing size or design complexity.

Sand Casting part
Large format 3D printing has helped us speed up the manufacturing process of our products, due to the confidence we have for the EXT Titan printers to work 24/7 without the need for special care during printing.
—Alonso Alvarez, CEO PSSI, Mexico-based pattern shop

Solving Sand Casting Patterns and Cores Manufacturing Challenges with 3D Printing

  • Faster Time to Market

    To be competitive, foundries and pattern shops must meet demands for fast production of patterns and core boxes, while still delivering high quality parts and the ability to adjust designs quickly and cost-effectively. 3D Systems solutions enable lights out manufacturing processes that can print a pattern quickly with pellet extrusion 3D printing and then machine the surface during or after the printing process for smooth, accurate patterns and core boxes.

    Machine in-situ or post printing for smooth, accurate surface finish

  • Machine in-situ or post printing for smooth, accurate surface finish

  • Design Complexity and Flexibility

    The layer-by-layer build of 3D printed casting patterns means foundries can quickly and inexpensively deliver what were previously impossible or difficult to produce geometries. Additive technology enables the creation of hidden voids, internal struts and blind holes that are beyond the geometric limitations of 6-axis CNC tooling. Gating, runners, and sprues can also be included.

    Print fast with pellet extrusion on our EXT Titan 3D Printers

  • Machine in-situ or post printing for smooth, accurate surface finish

  • High Quality Castings

    Maintaining dimensional accuracy and ensuring pattern durability are key to sand casting success and metal part quality. Our additive manufacturing solutions for sand casting use durable and affordable materials proven to run for thousands of cycles with almost no visible wear.

  • Sand Casting Pattern

  • Reduced Costs

    Beyond minimizing waste with additive manufacturing efficiency compared to traditional subtractive methods, our 3D printing solutions use the most cost-effective, yet durable materials. Labor is further reduced with lights out manufacturing capabilities, the ability to produce single-piece large patterns that don't require assembly, and minimized finishing with sooth pattern surfaces, all contributing to reduced cost per part.

  • Grey, natural hybrid pellets on a neutral background

Your Partner for 3D Printed Sand Casting Patterns and Core Boxes

  • We Offer Complete Solutions

    • Powerful software for CAD design, reverse engineering, inspection and 3D printing
    • Multiple 3D printing technologies that can deliver from complex geometries with outstanding surface finish, up to very large parts with the highest material deposition speeds
    • Best-in-class materials, including a wide range of affordable, high performance pellets
    • Tailored hardware to meet your needs, including pellet extrusion and hybrid additive + subtractive systems

  • Small to Large Parts Capacity

    • Large build capacities, up to 1.82m in length
    • Ideal for large parts that would typically require extensive labor for assembly
    • Seamless workflows for parts that exceed build volume

  • Applications Consulting

    • Robust network of experts in the 3D Systems Application Innovation Group (AIG)
    • Leverage AIG's years of sand casting and additive manufacturing experience
    • Dedicated team provides hands-on training and consultation from ideation to implementation

Learn More About our Solutions for Sand Casting

EXT 1070 Titan Pellet

EXT 1070 Titan Pellet

3D Systems’ flagship pellet extrusion printer capable of printing medium-to-large format parts, featuring a build volume of 1070mm x 1070mm x 1118mm (42" x 42" x 44").

plastic black pellets

EXT Titan Pellet Materials

Broad selection of commercial, flexible, engineering grade and high-performance polymers for 3D printing

a roll of plastic, light grey filament

EXT Titan Filament Materials

Broad selection of commercial, flexible, engineering grade and high-performance polymers for 3D printing

SLA 750 3D Printer

SLA 750

Industrial-scale additive manufacturing solution for stereolithography

accura composite piv thumbnail

Accura Composite PIV

High production speeds with exceptional stiffness/rigidity

3D Systems 3DXpert hero image

3DXpert

All-in-One Integrated Software for Industrial Additive Manufacturing

3D Systems ProX 950 3D Printer (SLA) large-format 3D printing

ProX 950

All the benefits of SLA 3D printing in extra-large format

3D Systems Accura Bluestone

Accura Bluestone (SLA)

Composite material for stable, high stiffness parts

Accura HPC Material

Accura HPC

High production speeds with exceptional stiffness/rigidity

Duraform AF+ SLS Piston

DuraForm ProX AF+ (SLS)

High stiffness, aluminum-filled Nylon 12 with metallic appearance

Geomagic Design X reverse engineering and 3D scanning software

Geomagic Design X

Reverse Engineering Software

a 3D rendering made from Control X software

Geomagic Control X

3D Inspection and Metrology Software

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  • Application Innovation Group

    Our team can help you solve your most difficult design and production challenges with additive manufacturing solutions. Together we’ll identify your needs, working with you to optimize your designs, prototype, validate and define a manufacturing flow.