3D Printing

3D Printed Sand Molds and Cores at Aurora Metals

At Aurora Metals, we're at the forefront of casting technology, proudly offering cutting-edge 3D sand printing capabilities for sand molds and cores. This innovative process allows us to produce complex, high-quality castings with unprecedented speed, precision, and flexibility. By harnessing the power of additive manufacturing, we're able to push the boundaries of what's possible in metal casting, delivering superior results for our clients across various industries.

The Aurora Metals 3D Printing Advantage

Our investment in 3D printing technology for sand molds and cores represents our commitment to staying ahead of the curve in the casting industry. This advanced process enables us to create molds and cores directly from digital files, bypassing traditional tooling methods and opening up a world of possibilities for our clients.

Toolless Production

One of the most significant advantages of our 3D printing process is the elimination of traditional tooling. This means:

  • Drastically reduced lead times for new parts
  • Lower upfront costs, especially for low to medium volume production
  • The ability to make quick design changes without expensive tool modifications

Unparalleled Design Freedom

Our 3D printing capabilities allow for the creation of incredibly complex geometries that would be impossible or prohibitively expensive with conventional casting methods. This means:

  • Optimized part designs for improved performance
  • Integration of features that previously required assembly of multiple components
  • The ability to create internal passages and structures that can't be achieved with traditional methods

Rapid Prototyping and Production

From concept to finished part, our 3D printing process accelerates the entire production timeline:

  • Prototype parts can be produced in days rather than weeks or months
  • Design iterations can be quickly implemented and tested
  • Seamless transition from prototyping to full production runs

Consolidated Assemblies

Complex core assemblies that traditionally required multiple pieces can often be printed as a single unit. This results in:

  • Reduced labor costs
  • Improved accuracy and consistency
  • Elimination of potential assembly errors

What We Do

Our Services

Aurora Metals offers a comprehensive suite of precision casting services, catering to diverse industry needs:

Lead Lined Wood Doors

Customizable sizes and veneers with fire labels up to 90 minutes.

01

Lead Lined Control Frame and Hollow Metal Doors

Available in custom profiles.

02

Lead Drywall

Our lead drywall is designed for easy installation, ideal for various structural applications to shield against harmful radiation.

03

Protective Glass

We offer protective glass with standard to enhanced shielding options, including safety laminated glass for door lites and side lites, ensuring safety and visibility in critical areas.

04

Lead Lined Steel Welded Doors & Frames

Designed for extreme door weights, custom jamb depths, and profiles with special hardware reinforcements.

05

Linear Accelerator Doors and PET Shielding

Tailored design for heavy radiation shielding.

06

Lead Plywood Interlocking Panel Systems and Lead Bricks

Available in a range of thicknesses and designs.
07

Applications of 3D Printed Sand Molds and Cores

Our 3D printing capabilities are suitable for a wide range of applications:

  • Rapid Prototyping: Quickly bring new designs to life for testing and validation
  • Low to Medium Volume Production: Cost-effective solution for smaller production runs
  • Replacement Parts: Create molds for obsolete parts without the need for original tooling
  • Complex Geometries: Produce parts with intricate designs that are challenging or impossible with traditional methods
  • Customized Components: Easily accommodate design variations without additional tooling costs

Our 3D Printing Process

  • Design Submission: We start with your 3D CAD file of the desired part
  • Design Optimization: Our experts analyze and optimize the design for the 3D printing process
  • Digital Mold Creation: We create a digital mold design, including gating and risering systems
  • 3D Printing: The mold or core is printed layer by layer using specialized sand and binders
  • Post-Processing: The printed mold or core is cleaned and prepared for casting
  • Casting: We pour molten metal into the 3D printed mold using traditional casting techniques
  • Finishing: The cast part is removed from the mold and undergoes any necessary finishing processes

Why Choose Aurora Metals for 3D Printed Sand Casting?

  • Expertise: We combine decades of casting experience with cutting-edge 3D printing technology
  • Speed: Significantly faster turnaround times compared to traditional tooling methods
  • Cost-Effectiveness: Reduced costs for complex or low-volume parts
  • Flexibility: Ability to quickly iterate designs and accommodate changes
  • Quality: High-precision parts with excellent surface finish and dimensional accuracy
  • Sustainability: Reduced material waste compared to traditional subtractive manufacturing methods

Integrating 3D Printing with Traditional Casting Expertise

At Aurora Metals, we see 3D printed sand molds and cores as a powerful complement to our traditional casting capabilities. By integrating this advanced technology with our time-tested expertise in metallurgy and casting processes, we're able to offer our clients the best of both worlds:

  • The precision and design freedom of 3D printing
  • The reliability and material properties of traditional casting methods
  • The ability to choose the most appropriate production method for each project

Our team of experienced engineers and technicians work closely with clients to determine the best approach for each unique application, ensuring optimal results in terms of quality, cost, and lead time.

Experience the future of casting with Aurora Metals. Whether you're looking to prototype a new design, produce a complex part, or streamline your production process, our 3D printed sand molds and cores can help you achieve your goals faster and more efficiently than ever before. Contact us today to learn how this revolutionary technology can benefit your next project and take your casting capabilities to the next level.

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