Case Study: KSB Limited achieves reduced lead times, improved part quality and lower production costs with ExOne S-Max® sand binder-jet 3D printing

India Steel Foundry Solved Complex Castings with Sand Binder Jetting

KSB Limited, the Maharashtra-based foundry division of the global KSB Group, faced long lead times, high tooling costs and frequent casting defects from traditional pattern-based sand casting while producing pumps, valves and custom components. To meet growing customer demands for faster delivery, lower costs and more complex geometries, KSB adopted ExOne’s binder-jet sand 3D printing solution, the ExOne S-Max®, to move to digital casting directly from CAD.

Using the ExOne S-Max®, KSB prints molds and cores with ±0.5 mm accuracy, integrates vents and gating, splits large parts for assembly, and reverse-engineers old components—eliminating hard tooling and many defects. The results: propeller impellers’ lead time fell from 8–10 weeks to 4 weeks and cost dropped ~50% (Rs.350,000 → Rs.175,000); a suction impeller was delivered in 3 days vs. 8 weeks; a large bell mouth was completed in 6 weeks (vs. 14) with costs down from Rs.3,400,000 to Rs.2,250,000; and NDE/DE covers went from ~16 weeks to 4 weeks with costs cut to Rs.145,000. ExOne’s technology thus enabled faster turnaround, improved part quality and significant cost savings for KSB Limited.

KSB Limited

Bhagwan Bagal

Head of Plant