Case Study: Boro Foundry Ltd achieves faster, tooling-free steam locomotive cylinder casting with ExOne 3D sand printing

Boro Foundry cuts lead time 50% with ExOne

Boro Foundry Ltd, a specialist in complex ferrous castings, faced the challenge of producing a one-off replacement cylinder for a historic steam locomotive. The part had complex geometry and no existing tooling, making traditional pattern-making prohibitively expensive. They turned to vendor ExOne and its On Demand Printing service using binder jetting technology to solve this.

ExOne produced a precise 3D printed sand mold for the cylinder, which enabled Boro Foundry to cast the part without any traditional tooling. This solution resulted in a 100% cost savings compared to pattern-making and a 50% reduction in lead time, while also achieving significant accuracy improvements that minimized post-processing.

Boro Foundry Ltd