3D printing of sand moulds on the FHZL PCM1200 in Almaty

Sand 3D printing services on the FHZL PCM1200 3D printer in Almaty from Exametra

Industry: automotive and mechanical engineering, aerospace, power engineering, art casting and design. Request: high-precision, high-quality casting. Equipment: FHZL PCM1200 3D printer.

Modern industry is going through a revolution driven by additive technologies. Among them, sand 3D printing holds a special place, fundamentally changing traditional casting processes. In Kazakhstan, and especially in Almaty, Exametra offers advanced services in this field using the industrial FHZL PCM1200 3D printer. With its impressive 1200×1000×600 mm build volume, this equipment opens new possibilities for manufacturers, engineers and designers, making it possible to produce complex casting moulds with unprecedented accuracy and efficiency.

What is sand printing?

Sand 3D printing is a type of additive manufacturing based on Binder Jetting. The process bonds sand particles layer by layer with special binders. The material is not ordinary river sand but specialised grades: silica, ceramic, chromite or synthetic sand, with optimal characteristics for casting. The process includes several stages:

• Creating a digital model of the future part in CAD software.
• File preparation: the model is sliced into layers by dedicated software.
• Printing: the machine deposits sand layer by layer and sprays a binder (for example, furan or phenolic resin) that bonds the sand particles according to the digital model.
• Post-processing: after printing, the mould is ready for use in casting with no additional baking.

Synthetic sand, controlled properties

Specialised tasks

Key advantages of sand printing

• High accuracy: dimensional deviations can be as low as ±0.3 mm.
• Complex geometry: the technology makes it possible to create internal channels, cavities and features that are impossible with traditional methods.
• Cost efficiency: eliminating expensive tooling makes the technology ideal for small-batch and one-off production.
• Speed: the cycle from digital model to finished mould takes hours or days, not weeks.
• Eco-friendliness: unbound sand is reused, which minimises waste.

Sand 3D printing is used in various industries that require high-precision, high-quality casting:

• Automotive and mechanical engineering: production of cylinder blocks, gearbox housings, chassis parts and other complex components that demand high strength and accuracy.
• Aerospace: manufacturing turbine blades, engine components and other parts with complex internal cooling channels and strict material requirements.
• Power engineering: producing large parts for wind turbines, hydroelectric plants and other equipment.
• Art casting and design: the technology makes it possible to realise complex artistic ideas and create unique decorative elements, sculptures and souvenirs.

Using Exametra's services lets companies gain all these benefits without capital investment in expensive equipment of their own, by ordering moulds and cores on demand.

About the FHZL PCM1200 3D printer

Exametra delivers its services on the industrial FHZL PCM1200 3D printer, a powerful and productive solution for printing large sand moulds. Technology: the machine uses the patented PCM (Patternless Casting Manufacturing) technology, an evolution of classic Binder Jetting. Its distinguishing feature is a two-component binder (furan resins) mixed directly during printing, which gives the moulds high strength and accuracy.

Key specifications

• Build volume: 1200 × 1000 × 600 mm, one of the largest formats on the market, allowing whole moulds to be printed for large castings.
• Print speed: up to 120 litres per hour or 18 seconds per layer. This delivers high productivity and short lead times.
• Layer thickness: 0.2–0.5 mm, which ensures high surface quality and geometric accuracy.
• Print resolution: 300×400 and 400×400 dpi.
• Materials: a wide range of sands (silica, calcined, synthetic, ceramic) and compatibility with regional and local binders, which lowers operating costs.

Benefits for Exametra customers

• Ability to print large, complex moulds for producing big, critical castings.
• High productivity handles both urgent prototypes and small-batch orders.
• Cost efficiency thanks to no tooling costs and the option to use local materials.
• A full cycle of services: from consultation and 3D scanning of the object and modelling through to printing and post-processing.

Summary

Adopting sand 3D printing is not just a modernisation of production but a strategic step into the future that opens opportunities to create new products, cut costs and enter new markets. Using the powerful FHZL PCM1200 3D printer, Exametra is ready to be a reliable partner for Kazakhstani companies. Whether it is prototyping a new part, small-batch production of highly complex castings or an urgent order, Exametra's services give access to advanced technology without significant capital investment. By working with Exametra you get not just a printed mould but a comprehensive solution, from technical consultation and optimising the model for casting to finished products that meet the strictest requirements.

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