Indian Steel Foundry Solved Complex Castings with Sand Binder Jetting

Digital casting with ExOne S-Max® 3D printer enables KSB in India to drastically reduce lead times, improve part quality, and lower production costs.

Before adopting 3D printing, KSB foundry in India produced castings just like any other in the country. The foundry relied on pattern-based molds, hence it had very long lead times and high costs, as well as often experienced casting defects and produced inaccurate parts. As times changed, the customer requirements for faster delivery, lower prices, complex geometries, and better quality pumps and valves became more and more demanding, which could hardly be fulfilled by conventional casting methods.   

To address these challenges and be one step ahead of its competitors, the foundry decided to tap into digital casting in 2022 and acquire ExOne’s binder jet sand 3D printing technology, the S-Max® 3D printer. 

The foundry shared that it could complete many complex casting projects successfully with the aid of the S-Max 3D printer. 

“ExOne’s binder jet sand 3D printer has revolutionized KSB‘s capabilities to deliver the components in record time and positioned us at the forefront of meeting customer needs," said Bhagwan Bagal, Head of Plant at KSB Limited.

Download the case study to get insights into the foundry's digital casting projects:

1. Develop propeller impellers with high dimensional accuracy and high-quality
2. Produce an urgently required suction impeller within three days
3. Develop a casting larger than the build area of the printer’s job box
4. Reproduce old, damaged parts rapidly with reverse engineering and sand 3D printing