Case Study: Amerequip Corporation cuts tooling costs and slashes lead time with ExOne's S-Max 3D sand printing

3D printed core saves thousands in tooling costs and reduces lead time by weeks

Amerequip Corporation needed to convert an 11-piece, laser‑cut welded assembly into a one‑piece design to reduce weight, improve quality, lower costs, and meet a tight schedule for Fall 2020 production. They partnered with Neenah Foundry and used ExOne's S-Max® binder‑jet sand printing (produced at Hoosier Pattern) to accelerate development of sample cores and avoid long core‑box lead times.

Neenah redesigned the part as a single ductile‑iron casting using a one‑piece core, and ExOne’s S-Max printed sand cores enabled sample delivery in under 2 weeks versus a traditional 6‑week lead time. The collaboration cut core‑box modification costs by $5,000, reduced part weight by 2.2 lbs, and improved quality and efficiency; the swing frame passed testing for planned 2020 use and earned Neenah the 2019 American Foundry Society “Casting of the Year.”

Amerequip Corporation