Feasibility of 3D Printing in INDIA- Neev

TechnoCast, Rajkot.
Neev Techno cast is one of the few supplier in India who has ExOne
S-MAX printer installed in its base.

The details of Printer are as follows:

Max. size
Moulding sand

: 1800 x 1000 x 700mm (70.9 x 39.37 x 27.56 in.)

: Silica sand of different grain size

Binder-type
Binder-content
Layer thickness
Accuracy

: cold-curing furan resin

: adjustable between 0.9 - 2.1 weight %
: 200 - 400 m; standard 300 m
: 0.1 % (max. 0.3 mm)

The printer is able to print 3D sand molds, cores etc. The sand which it
uses is imported from Germany and not the normal Green sand. The
methoding of Gating system, riser, runner is also included in the
printing via this printer. For larger sized parts the mold design can be
done by breaking into halves further.

It is not used for direct metal printing ie we cannot directly get the
casting printed in it but only the sand mold printed in it.

PROCESS OVERVIEW & LEAD TIME:

The lead time for a prototype part is around 4 weeks.
The detailed process breakup with individual breakup time is as follows:

Design Validation at their end

--- 2 days
Mold designing (NX software)
--- 4 to 5 days
Simulation (ProCast)
--- 2 days
3D Printing of Mold and cores
--- 4 days
Mold Printing
--- 2 days
Soaking period
---1 day
Vacuum cleaning & brushing --- 1 day

Mold Assembly & Casting Pouring

--- 1 day

Fettling, Shot Blasting etc.

Heat Treatment if Required
Analysis & Testing of Test Bars
Casting Inspection
Machining, Inspection & Dispatch

--- 1 day
--- 3 days
--- 1 day
--- 1 day
--- 7 days.

For Casting it will take around 3 weeks and if we go for machining at

other place with our developed suppliers, transportation time needs to
be included beyond this time.

Facility Overview :
The unit overall strength is around 45 members including the machining
unit strength.
Casting Facility:
Has in-house experience in Aluminum and Cast Iron metal pouring
only.
SiMo and GGG40F grade pouring to be outsourced.
Have an outsourced Casting Supplier or partner in Rajkot RISHI
CAST who can pour in our desired grade.
Inexperienced in bigger parts but have done casings for small
turbochargers of Honeywell.
Fettling and Shot blasting also to be done at external source.
Painting Shop not available.
TUV 9001 certified.
Designing of mold, cores, gating system to be done In-house using
different software like Siemens, Geomagics etc.
Have good experience in automotive parts like clutch housing etc.

MACHINING FACILITY :
The machining unit is setup in the city which is soon going to be
changed to other location near to casting facility.
The list of machines are as follows:
1 unit: Haas Automation VF2 (762 x 406 x 508 mm)
4-axis milling center
1 unit: Jyoti Huron VMC 640 (600 x 400 x 460 mm)
4-axis milling center customized
1 unit: Jyoti Huron VMC 1050 (1020 x 510 x 510 mm)
4-axis milling center customized
1 unit: TAL HMC H - 40 (680 x 430 x 480 mm)
3-axis Milling Center (OUT SOURCED)
1 unit: VTL (600 mm Max. working Dia.)
5 units: Turners.

INSPECTION FACILITY:
CMM installed of Carl Zeiss (700 x 1000 x 600) at new machining
facility
New CMM of Bigger size to be purchased soon.
3D scanning with blue LED Technology
Spectrometer, UTM, X-Ray scanning, hardness testing, Image
Analyzer testing all are outsourced.

Packing is normally done, first the component is wrapped in VCI film

and then packed in corrugated box.

Parts Feasibility:
Turbine Casing HZTL118086P0003:
Compressor Casing HZTL118597P0001:
In context of 3D printing of mold the supplier is quite confident upon
himself. With regard to the castings he is confident that his casting
partner Rishi Cast will be able to pour the castings in our desired
grade and supply us good castings.
As of now, sizing is not the concern for him. He is ready to go for size of
compressor casings also. He do not have any problem in printing the
mold of it.
Neev Technocast has done similar casings of Honeywell Turbo but the
size is smaller for that and the material was also Stainless Steel.
On a conclusive note supplier feels confident that he can go ahead with
the process.
Commercial feasibility hasnt been discussed as NDA hasnt been signed
till yet, so we cannot leave the model and drawings at his end. This can
be done once we decide whether to go for it or not.