Case Study: Case New Holland achieves rapid, scalable metal casting and halves pattern lead-times with 3D Systems SLS using DuraForm & CastForm

Case New Holland Uses DuraForm and CastForm SLS Materials for Casting

Case New Holland (CNH), a global agricultural and construction equipment manufacturer in New Holland, PA, brought solid imaging in‑house to solve chronic pattern‑making problems. Previously reliant on service bureaus, CNH faced dimensional instability, moisture sensitivity and long lead times, yet routinely needed 20–50 cast metal prototypes and flexibility for a range of applications. Their goal was a faster, more stable way to produce sand casting and prototype parts.

CNH purchased an SLS system (Vanguard™ si2, now sold as the sPro 60 SD) and began using DuraForm for sand casting patterns and CastForm PS for investment casting. By producing segmented patterns and insert-mounted matchplates, they reliably obtained 50+ castings, converted some patterns into low‑volume production runs (up to ~1,200 parts), and expanded into steel investment casting without costly tooling. The change cut pattern‑making time by half or more (casting in days versus 3–4 weeks), improved foundry handoff and accelerated the path from prototype to production.

Case New Holland

Luke Nolt

Casting Specialist