Case Study: Kore Mart achieves production-scale, low-scrap sand core manufacturing with ExOne S-Max binder jet 3D printing

3D Printing Solutions for High-Scrap Assembled Cores

Kore Mart, a Pennsylvania-based foundry supplies company, faced high-scrap rates and tooling limits when producing complex assembled sand cores. To modernize production and reliably deliver intricate geometries at scale, Kore Mart installed an ExOne S-Max® binder jet sand 3D printing system to replace hard tooling and manual assembly processes.

Using the ExOne S-Max, Kore Mart prints directly from CAD to eliminate tooling setup, reduce scrap on intricate assemblies, and speed production. Within three months the S-Max was running at about 50% capacity—producing five to six large-format build boxes per week—meeting the precision needs of roughly 98% of customers and delivering an estimated payback in under two years; Kore Mart is already planning a second ExOne S-Max to expand capacity.

Kore Mart

Greg Witmyer

President