Case Study: Liberty Pattern achieves faster, high-strength aerospace core production with ExOne’s Phenolic Direct Binding sand 3D printing

Liberty Pattern expands to three ExOne S-1000 printers for aerospace core production

Liberty Pattern, a U.S. tooling and pattern-making company specializing in aerospace components, faced a challenge in meeting growing customer demand for greater speed, precision, and prototyping flexibility. Their traditional sand tooling methods could not compete with the rapid iteration and design freedom offered by additive manufacturing. They turned to vendor ExOne for a solution that specifically utilized the Phenolic Direct Binding (PDB) process.

The solution implemented by ExOne was the installation of three VX1000 sand 3D printers. This allowed Liberty Pattern to print high-strength cores using a recyclable sand media, which significantly lowered the risk of casting defects and minimized costly rework. The results included drastically reduced tooling and lead times for faster turnaround, the ability to quickly validate designs before full-scale production, and a boost in first-pass yield. ExOne's technology positioned Liberty Pattern to better serve the aerospace industry's demand for complex components.

Liberty Pattern