Case Study: Morel Industries halves lead time and cuts scrap from 9% to 1% with ExOne

Complex Digital Core Cuts Lead Time in Half & Saves Thousands

Morel Industries faced high scrap and long lead times caused by manual assembly of wooden core boxes for complex exhaust manifold cores. They worked with ExOne, using ExOne’s digital sand-printing/digital printing process to address the human-error-prone, multi-pattern workflow.

ExOne printed a single, integrated core (combining three cores into one) with vents and intricate geometry, eliminating tooling and core shift. The ExOne solution cut scrap from 9% to 1%, reduced lead time from 5 weeks to 2 weeks (a 60% reduction, shaving three weeks), and lowered batch cost from $8,000 to $1,200 (about an 85% savings).

Morel Industries