Case Study: Maschinenfabrik Liezen und Gießerei (MFL) achieves lighter, longer‑lasting, lower‑CO2 spring cup with ExOne S‑Max® Pro

Topology Optimized Spring Cup for Rail Vehicles

MFL (Maschinenfabrik Liezen und Gießerei) set out to reduce the carbon footprint, material use and operating impact of a safety‑critical spring cup used in rail vehicles. Facing industry pressure for lighter components while maintaining strict safety and durability standards, MFL joined the Inno‑Up research consortium with partners including ExOne, using ExOne’s sand 3D printing capability (S‑Max® Pro) to explore topology‑optimized castings and more resource‑efficient production.

The team combined topology optimization with 3D‑printed sand core packages produced on the ExOne S‑Max Pro and conventional casting at MFL to realize the new design. ExOne’s printing enabled complex cores and a redesigned geometry that cut spring cup weight by 21% (62 kg → 49 kg), reduced melt by 13 kg per part, lowered CO2 by 7 kg and energy cost by €2 per component (≈15% improvement in manufacturing impact), and saves about €2,900 in total energy costs per train (72 parts); the project also won an innovation award for its environmental benefits.

MFL

Markus Schmid

MFL