Case Study: Grunewald achieves faster, higher-volume prototype casting with ExOne 3-D sand printing

New Perspectives Through 3D Printing

Grunewald, a prototype foundry in Bocholt, Germany, faced pressure to deliver more complex, lighter-weight cast parts faster for automotive and EV prototype programs while offsetting a downturn in conventional tooling work. To meet that challenge the company invested in an ExOne 3-D sand printer (Type S‑Max Plus) at the end of 2018 to produce printed sand molds and cores for aluminum casting.

Using the ExOne system, Grunewald moved to near 24/7 production of 3‑D printed molds and cores, cutting lead times by about 4–6 weeks, completing a 1,260 L job box in 24 hours, and executing runs such as 1,500 printed chassis parts. The investment (printer and peripherals ~EUR 1.3 million) helped grow the foundry’s share of group sales from roughly 50% to 75% and materially increased throughput and design freedom for customers.

Grunewald

Ulrich Grunewald

Managing Director of the Corporate Group