Our hands shape your success

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. Learn more about the comprehensive competencies in our Additive Manufacturing Center and our process chains for prototype and series production.

GF Casting Solutions Leipzig - our skills at a glance

Prototyping with 3D-printed sand cores

These steps are important, before we can start with the printing process:

1. Computer Aided Design (CAD)

Casting optimization of components // Design adaptation of components // Finding the optimal manufacturing process for prototyping and volume production

2. Magma simulation

Casting simulation: no production of scrap // Proprietary material database for accurate determination of all cooling situations in printed and molded sand

3. Data preparation for the 3D-printing process

Job box setup // Maximization of box utilization through cost-efficient and sustainable production

Impressions from the CastForge 2022

Thanks to everyone who visited our booth at Messe Stuttgart, where we presented full-size as well as downsized off-highway and commercial vehicle components cast to scale, and a hydraulic rotary transmission with its 3D-printed sand core.

Sand 3D printing and iron casting

In these steps, a prototype or a serial product is created:

3D printing

Printing (production in cold-hardening phenolic resin) // Unpacking the printing box

Iron casting

Insertion of the printing form at the molding machine // Mold assembly (near-series casting and feeder systems) // Finishing of the components // Casting of the mold

Innovation center for 3D-printed sand cores

Since June 2018, our iron casting plant in Leipzig (DE) has had its own innovation center with a team working on additive manufacturing and its application for sand cores used in iron casting.

Innovation center for 3D-printed sand cores

Machining in iron casting

After these 5 process steps, prototypes and series products are ready for installation:

Blasting of the components
Cleaning of components (use of cleaning robots for serial production - automation)
Quality testing (offering all common tests: saw testing, dye penetrant testing, ultrasonic testing, FOM, magnetic crack testing, etc.)
Undercoating (According to customer's request)
Shipping

About our location: Leipzig (Germany)

Machine-molded iron cast components for commercial vehicles and the off-highway segment including construction equipment, agricultural and forestry machinery, regenerative energy, engine technology and general engineering.

Leipzig