Case Study: Standard Alloys achieves 57-inch impeller casting in under 8 weeks with ExOne’s rapid 3D sand printing

Manufacture a 57 Inch Impeller without a Core Box with ExOne’s Rapid Casting Process

Standard Alloys needed to dramatically shorten the traditional sand casting timeline to meet critical lead times for a 57-inch impeller. They partnered with ExOne and used ExOne’s Rapid Casting Process—3D sand printing of cores directly from CAD—to avoid building a pattern-based core box and accelerate delivery.

ExOne printed Standard Alloys’ largest RCT core to date (one core printed in sections and pieced together), producing sand cores in less than a week and taking the project from concept to completion in under eight weeks versus several months with traditional methods. ExOne’s process eliminated weeks of core box lead time, improved dynamic and hydraulic balance through digital accuracy, and cut post-processing and balancing from days to hours, enabling serviceable impeller castings in under two months.

Standard Alloys