Case Study: Zalewa Tec achieves rapid, cost-efficient production of 3D-printed sand molds and cores with ExOne S-Max®

Successful European Start-Up Supports 3D Printing for Foundries and Beyond

Zalewa Tec, a start‑up based in Großschirma, Saxony, supports foundry, automotive and heavy‑machinery customers but faced typical industry pain points: time‑consuming pattern storage and maintenance, high repair costs, geometric design limits, a skills shortage and strong demand for faster, higher‑quality turnaround. To address these challenges the company partnered with ExOne and invested in the ExOne S‑Max® binder‑jet system (double job box).

ExOne’s S‑Max® enabled a seamless digital workflow from 3D scanning and CAD to printed sand molds and cores, eliminating physical patterns and allowing assembly of larger parts. The solution delivers complex geometries in under 16 hours, yields up to 90% cost savings for small runs (example: 50 parts), improves surface quality and responsiveness (orders can be completed as quickly as the next day), and uses optical scanning and documentation for quality assurance—results that have driven rapid growth and plans for a second S‑Max® to double capacity.

Zalewa Tec

Stefan Meutzner

Co-Founder