Case Study: Demir Engineering achieves rapid, first‑pour castings and 5‑day turnarounds with ExOne S‑Max Pro

Fit-For-Purpose Engineering Solutions with Sand 3D Printing

Demir Engineering Ltd., an Edmonton-based materials and metallurgical engineering firm serving heavy industries, needed faster, fit-for-purpose castings to avoid costly downtime and long OEM lead times. To support just-in-time inventory, rapid replacement parts, and complex prototypes, Demir invested in an ExOne S-Max Pro binder-jet sand 3D printer (using silica sand and furan binder) and integrated 3D scanning, CAD modeling, and simulation into its digital workflow.

Using ExOne’s S-Max Pro to print molds and cores directly from digital files, Demir runs front-end simulations to ensure first-pour success and can have mold packages ready in as little as 24 hours. The ExOne solution delivered measurable results: a mining coupling that an OEM quoted at five–six months was reverse‑engineered, printed, cast, and machined in five days (for a customer facing estimated downtime costs of $40,000/hour), allowed Demir to retire conventional tooling, reduce scrap and carbon footprint, add a second job box within a year, and scale daily production.