Precision Casting
Industrial manufacturing technology based on the lost-wax process used in the aerospace and energy industry to produce turbine blades and structural parts with complex shapes and cooling systems.
Our capabilities
- Gating & Tooling designs
- Casting filling, solidification
- Defects prediction simulation
- Core & ceramics recipe definition
Precision casting and post-processing
Additive manufacturing
Our accelerative technology
GF Casting Solutions has long-standing expertise in metal processing and serial production. With our manufacturing technologies, we develop and supply ready-to-mount solutions for customers in several market segments. With additive manufacturing, we provide even more speed and flexibility.
Metal 3D-printing for aerospace, space and energy solutions
With the AMotion Center in the Switzerland, GF Casting Solutions has founded a strongly focused competence center for Additive Manufacturing . The additive manufacturing process maximizes the design flexibility and allows the integration of additional functions due to the absence of tooling. Geometries are no longer limited to the possibilities of traditional technologies. With printing space as big as 500 x 500 x 500 mm, we offer serial production of large additive manufactured components with extremely complex shapes integrating more details and functions.
We support you with long-standing experience from decades!
- From the very first design concept to serial production
- Topology optimization from the very beginning
- Selection of most suitable alloy for high performance applications
- Combination of several parts and high-level functional integration
With our expertise, we provide the ideal design with funcitonal integration.
Value add in metal 3D-printing
Machines and material capabilities
Technology
Laser Powder Bed Fusion (EOS M290)
Laser Powder Bed Fusion (DMP Factory 500)
| Technology | Laser Powder Bed Fusion (EOS M290) | Laser Powder Bed Fusion (DMP Factory 500) |
| Materials | Inconel 718 Inconel 625 Hastelloy X |
Inconel 718 Inconel 625 Hastelloy X |
| Dimensions | 250 x 250 x 280 mm | 500 x 500 x 450 mm |
| Laser type / nr | 400 W X 1 | 500 W X 3 |
| Machine number | 2X already in production | 4X already in production |
Areas of application
Energy
3D-printed demonstrator for industrial gas turbines
- Dimensions: 498 x 498 x 425 mm
- Material: Alloy X
- Density: 8.2 g/cm3
- Weight: 29.7 kg
- Volume: 3626 cm2
Space
3D-printed demonstrator for combustion chambers
- Dimensions: 425 x 365 x 420 mm
- Material: Inconel 718
- Density: 8.2 g/cm3
- Weight: 20 kg
- Volume: 2576 cm3
Aerospace
3D-printed demonstrator for turbine rear vanes
- Dimensions: 96 x 499.7 x 499.7 mm
- Material: Inconel 718
- Density: 8.2 g/cm3
- Weight: 7.3 kg
- Volume: 899.540 cm3
Motorsport
3D-printed demonstrator for motorsport applications
- Dimensions: 283 x 264 x 445 mm
- Material: Inconel 718
- Density: 8.2 g/cm3
- Weight: 19.5 kg
- Volume: 2373.5 cm3
New challenges need new technologies
GF Casting Solutions is ready to realize your 3D-printing challenge!
With GF as your additive manufacturing partner you benefit from:
- Short development cycles
- Unlimited possibilities in terms of shape
- Wide variety of materials
- Know-how in serial part production
- In-house Research and Development team
- Post-processes in-house
- Fully certified value chain
Our certificates
Product quality and customer service have always been the main goal for GF Casting Solutions. The Management-Team in Novazzano keeps control of the Quality Management System by performing regularly reviews aimed at verifying its adequacy, effectiveness and efficiency, ensuring that the objectives assigned in accordance with the Quality Policy have been attained and designing improvement and risk mitigation plans where necessary. The loyalty of our customers and compliance certification and accreditation to the international EN 9100; ISO 9001 and ISO 14001 standards are testimony to the effectiveness of our Quality Management System.
Nadcap certified production of precision casting and additive manufacturing
Certificates of our location in Novazzano & Stabio
- NADCAP Welding - GF Casting Solutions Novazzano SA (PDF/ 357 KB)
- NADCAP Welding - GF Casting Solutions Stabio (PDF/ 365 KB)
- NADCAP Non Destructive Testing - GF Casting Solutions Novazzano SA (PDF/ 374 KB)
- NADCAP Heat Treatment - GF Casting Solutions Novazzano SA (PDF/ 374 KB)
- ISO 9001 - GF Casting Solutions Novazzano SA (PDF/ 541 KB)
- ISO 9001 - GF Casting Solutions Stabio (PDF/ 162 KB)
- ISO 14001 - GF Casting Solutions Novazzano SA (PDF/ 256 KB)
Our solutions
... for aeropsace
Turbine Rear Vane
Technology
DMP Factory 500
3DXpert Software
CUT E 600
3DXpert Software
CUT E 600
| Technology | DMP Factory 500 3DXpert Software CUT E 600 |
| Material | Inconel 718 |
| Laser power | 3 x 500 W |
| Laser thickness | 60 µm |
| Surface Quality | Ra 7-12 µm |
| Built time | 48 hours |
Your Advantage
- Largest seamless part of the market
- Shorten lead time
- Decrease manufacturing costs
- Combine functionalities
Fuel Injection nozzles
Technology
DMP Factory 500
3DXpert Software
CUT E 600
3DXpert Software
CUT E 600
| Technology | DMP Factory 500 3DXpert Software CUT E 600 |
| Material | LaserForm® Ni718 |
| Laser power | 3 x 500 W |
| Layer thickness | 60 microns |
| Surface roughness | 7-12 µm Ra |
Your Advantage
- Eleminated assembly steps
- Less material is used
- Reduced weight with increased total stiffness
... for the energy segment
Single Crystal Blade
Application
Industrial Gas Turbines
| Application | Industrial Gas Turbines |
| Process | Investment Casting |
| Material | CMSX4 |
| Weight | 100-400 g |
| Size | 150 x 50 x 20 mm |
| Technology | Vacuum Melt - Single Crystal |
Burner
Application
Industrial Gas Turbine
| Application | Industrial Gas Turbine |
| Process | Investment Casting |
| Alloy | Hast X |
| Weight | 10-20 kg |
| Size | 350 x 200 x 200 mm |
| Technology | Vacuum Melt - Equiax |