Voxeljet AG stands as a significant innovator in industrial additive manufacturing, particularly through its advanced binder jetting technology. This German company has consistently pushed the boundaries of 3D printing, enabling the production of complex geometries and large-scale components for various industrial applications. Their systems are designed for high throughput and precision, addressing critical needs in modern manufacturing.
The company’s foundational approach centers on powder-based additive manufacturing, which allows for the creation of intricate parts from diverse materials, including specialized sands and polymers. This method provides a tool-less production pathway, significantly reducing lead times and manufacturing costs compared to traditional methods.
Industrial Binder Jetting Technology Fundamentals
Binder jetting is a layer-by-layer additive manufacturing process where a liquid binding agent selectively joins powdered material. A recoater mechanism first spreads a thin layer of particulate material across a build platform. Subsequently, an inkjet printhead precisely deposits binder droplets onto specific areas, solidifying the powder to form a cross-section of the part.
This sequence repeats, building the object vertically until completion. Unprinted powder remains loose, serving as a natural support structure for complex geometries and internal features, which simplifies post-processing. Voxeljet’s Universal Binder Jetting (UBJ) technology supports a wide array of materials, including various industrial foundry sands, PMMA, and ceramics, offering exceptional material freedom.
The process is highly adaptable, allowing for the use of cost-effective, locally available sands with high recyclability. Layer thicknesses can range up to 0.04 inches, accelerating the build process and contributing to reduced operational costs. Integrated process sensors provide real-time monitoring of critical parameters, ensuring consistent print quality and traceability throughout the manufacturing cycle.
Advancements in Large-Scale Sand Mold Printing
| System Model | Technology | Build Volume (L x W x H) | Key Application | Resolution (DPI) |
|---|---|---|---|---|
| VX4000 | Binder Jetting | 4000 x 2000 x 1000 mm | Large Sand Molds | Up to 200 |
| VX7000 | Binder Jetting | ~7000 x 7000 x 1000 mm | Industrial-Scale Sand Molds | Not specified, high precision |
| VX9000 | Binder Jetting | ~9144 x 7010 x 1829 mm (30 x 23 x 6 ft) | Multi-Ton Cast Components | High dimensional accuracy |
| VX1000 HSS | High Speed Sintering (HSS) | 1000 x 540 x 400 mm | Functional Polymer Parts | Not specified, high performance |
Voxeljet has pioneered large-format 3D printing systems for sand molds, addressing the demand for multi-ton cast components. Systems like the VX4000, VX7000, and the colossal VX9000 exemplify this capability, offering build volumes that far exceed conventional additive manufacturing limits. The VX4000, for instance, boasts a continuous build volume of 4 x 2 x 1 meters.
The VX7000, a more recent development, features an approximate build volume of 7 x 7 x 1 meters and can process over 60 tons of sand in a single job. This system employs a reversed build approach where the printhead and recoater move upward, ensuring consistent surface quality over vast areas. It also incorporates a fully integrated sand logistics system for continuous material feeding.
The VX9000, developed in collaboration with GE Vernova and Fraunhofer IGCV, is designed for components in the multi-ton range, with a build volume of 30 x 23 x 6 feet. This system has successfully produced 9.5-meter-long sand molds for industrial castings, demonstrating exceptional dimensional accuracy and fitting precision for large-scale parts.
Precision in Metal Casting Core Production
Producing intricate metal casting cores is a core application for voxeljet’s binder jetting technology. This tool-less method enables the creation of complex internal geometries and thin-walled structures that are often challenging or impossible with traditional core-making processes. The flexibility extends to various metals and alloys, including magnesium, aluminum, gray iron, steel, and gunmetal.
Voxeljet’s systems facilitate the production of sand cores with specially matched sand-binder combinations, optimizing casting results for both small and extremely large components. Build volumes for these applications range from 300 x 200 x 150 mm³ up to 4,000 x 2,000 x 1,000 mm³, accommodating casting weights up to approximately 80 tons.
The VJET X technology represents a significant leap in additive mass manufacturing of sand cores, particularly for the automotive industry. This process is ten times faster than previous models, achieving layer times under five seconds. It utilizes inorganic binder systems, ensuring zero emissions during core printing, storage, and the casting process, aligning with modern environmental standards.
High-Speed Additive Manufacturing Systems
Beyond sand printing, voxeljet offers High Speed Sintering (HSS) technology for producing functional polymer parts. HSS combines aspects of binder jetting and selective laser sintering, using an inkjet printhead to deposit an infrared-absorbing fluid onto a polymer powder layer. Subsequent infrared light exposure selectively melts and fuses the underlying powder.
HSS technology yields polymer components with properties comparable to those achieved through injection molding, making it suitable for functional prototypes and end-use parts. Materials such as PA12, PP, TPU, PEBA, and EVA can be processed, offering significant material freedom and rapid variant changes.
The VX1000 HSS system, with a job box dimension of 1000 x 540 x 400 mm, provides substantial build volume for cost-efficient production of small to medium-sized batches, and even mass production when automated. Its robust design supports continuous industrial multi-shift operation, ensuring maximum output and reliable planning.
Enterprise-Level 3D Printing Solutions
Voxeljet extends its technological prowess through comprehensive enterprise 3D printing solutions, including a global network of service centers. These centers in Germany, the USA, and China provide on-demand manufacturing of molds, models, and functional polymer parts, supporting rapid prototyping and small to medium series production.
The company’s services encompass data preparation, optimization of CAD data for production, and even reverse engineering from existing components. This integrated approach allows customers to leverage additive manufacturing without significant upfront investment in equipment, ensuring quick turnaround times and access to specialized expertise.
Voxeljet’s systems are designed for seamless integration into partially or fully automated production environments. This capability, combined with their expertise in various casting processes and metal materials, positions them as a critical partner for industries seeking to modernize their manufacturing workflows and achieve high-volume additive production.