Case Study: Österreichisches Gießerei-Institut achieves a 36% lighter, ready-to-install topology-optimized casting in one week with ExOne S-Print®

Reverse Engineering and Topology Optimization with 3D Sand Printing

Österreichisches Gießerei-Institut (ÖGI), the Austrian Foundry Institute, needed to replace a welded steel agricultural machine assembly with a lighter, topology-optimized casting as part of the multi-partner Inno-Up research project. To do this, ÖGI partnered with ExOne and used the ExOne S-Print® sand 3D printing system to combine topology optimization, FEM analysis and casting simulation with the ability to locally tailor material properties.

ExOne’s S-Print® was used to rapidly produce 3D‑printed sand molds and cores while ÖGI applied topology optimization, casting simulation and targeted air-cooling to cast the part in GJS-500. The result: a ready-to-install casting delivered within one week, reduced from 3.9 kg to 2.5 kg (−1.4 kg, 36% lighter), meeting strength and hardness targets in destructive and metallographic tests, and demonstrating shorter lead times, reduced resource use and lower lifecycle emissions.

Österreichisches Gießerei-Institut

Aldo Randazzo

Member of the Project Team