From the idea to series production, we supply everything out of one hand - GF Casting Solutions Leipzig operates the foundry with Europe's largest moulding box for machine-moulded iron casting.
No matter what challenges you face, we support you throughout the supply chain and strive to become your development partner. We offer comprehensive know-how and competencies for several market segments like construction equipment, forest and agricultural machines, hydraulics or robotics. Learn more about our process chain for prototyping and serial production.
We offer the whole value chain
1. Computer Aided Design
Our team of experts uses CAD to optimise the design of the components. In this context, topology optimisation is an important tool for learning from nature and for designing components bionically. In this way, we strive to meet customer requirements as detailed as possible and ensure optimal manufacturing results. In cooperation with our customers, costs and function can be optimised. Especially by using 3D printing, functional integration can be combined with maximum design freedom. Together we shape the future.
2. Simulation
A detailed understanding of the part geometry and process parameters ensures that we meet our customers’ requirements in the best possible way. With the help of simulation, time- and cost-intensive tests can be significantly minimised in advance, which gives our customers a tremendous opportunity to reduce time-to-market.
Critical areas in the part are identified at an early stage and can be optimised specifically. In addition, this ensures the high quality standard that GF offers its customers and, by reducing scrap and rework, increases sustainability throughout the entire process.
3. Data preparation
To produce prototypes, spare parts or smaller quantities, we use our innovation center for 3D printed sand cores. To print sand cores, the digital CAD model is divided into layers, and later, the laser in the printer will print these layers into the job box - one by one. The preliminary modeling work is necessary to maximise the utilisation of the job box: we fit as many parts and structures as possible into the available space to increase process efficiency and sustainability.
4. 3D printing process
Based on the corresponding part slices, sand is distributed in the job box, followed by a binder. Print layers are applied one by one. After each application, the job box moves downward by the thickness of one slice. The steps repeat until the entire job box is filled and the desired sand model is completely built up. The printed cores and moulds are unpacked and the excess sand gets removed and reused, which ultimately contributes to a circular economy.
5. Casting process
Our moulding box, the largest in use across Europe and North America, increases process speed, accuracy and efficiency. By printing both cores and moulds, we can provide parts with short lead times for early stage testing, assembly testing and more. Various materials are available for producing prototypes and for serial production: grey cast iron, steel, and aluminium (also in cooperation with other foundries). State-of-the-art automation is used to clean the parts via shot blasting/grinding.
6. Quality testing and assurance
In order to ensure a reproducible high quality for each component, we carry out a variety of tests. For example, ultrasonic tests and magnetic crack testing, also dye penetration testing or X-ray testing. Based on these procedures as well as our know-how, our customers can be sure that their component meets the desired requirements and withstands the calculated loads.
7. Coating
We offer various services for finishing and refining components following quality testing. For example, to reduce unnecessary costs, we provide support for design optimisation before starting series production. After the parts are produced, we apply various coatings, such as a primer or top-coat, based on customer specifications. This provides corrosion protection during transport and warehouse storage. The parts are immediately ready for further processing or use upon delivery with no additional time or expense for removing rust film.
8. Machining
Components can also be machined following production to meet customer requirements. These processes can be performed by external partners or in-house, which is preferred for 3D-printed parts. Our equipment includes a 5-axis CNC milling center and measuring machines. We also assemble components and sub-components and provide various logistics services. Our customers can expect quick delivery times and 3D-printed parts that are immediately ready for installation. Moreover, because GF is a full-package supplier, customers get everything from a single source. Our hands shape your success.
