3D Sand Mold Printer Buying Guide (Part 2)

5. Stability and reliability of 3D sand printing equipment

The importance of stable operation of equipment:

In the production of castings, the stability of equipment is very important. When the equipment fails, it may lead to production interruptions, affecting the delivery schedule and bringing great economic losses to the enterprise.

Especially for continuous production foundries, the stable operation of equipment for a long time is the basis for ensuring production efficiency and product quality. For example, in the production line of auto parts, if the 3D printer frequently fails, it will lead to the line being stalled, affecting the production progress of the entire vehicle.

How to check the stability and reliability:

Check the manufacturer’s quality control system:

Learn the manufacturer’s production quality management process, including raw material procurement, component processing, assembly and debugging and other aspects of quality control measures.

A manufacturer with a good quality control system can often produce more stable and reliable quality equipment. For example, some well-known manufacturers conduct strict quality testing on each component to ensure that it meets high quality standards.

Equipment failure rate data:

Ask the manufacturer to provide equipment failure rate statistics, including average failure-free operation time, failure frequency, etc. These data can visualize the reliability of the equipment.

At the same time, you can search through the network, consult other users, and other ways to understand the failure rate of the equipment in actual use. For example, the equipment use experience shared by some users on the forum can provide us with reference.

User Reputation:

Talk to users who have used the equipment to understand their assessment of the stability and reliability of the equipment. The actual use experience of users is the most direct and authentic feedback.

You can participate in industry exhibitions, join professional communities and other ways to establish contact with other users to get their opinions and suggestions. For example, some foundries will prioritize brands with good reputations in the same industry when selecting equipment.

6. Software support

Excellent software features and functions:

Model processing:

Powerful 3D printing software can effectively process complex casting models, including model repair, optimization, slicing and other functions. For example, for some models imported from CAD software that may be defective or unsuitable for printing, the software can automatically detect and repair these errors to ensure that the model can be printed smoothly.

Printing parameter settings:

The software should provide a variety of printing parameter settings, such as printing speed, layer thickness, nozzle temperature, binder dosage.

Users can accurately adjust these parameters according to different casting requirements and material properties to obtain the best printing results. For example, for thin-walled castings, you may need to adjust the layer thickness and printing speed to ensure the strength and accuracy of the sand mold.

Production process management:

The software should also have production process management functions, including order management, task scheduling, equipment monitoring, etc.

This can help foundries carry out effective production management and improve production efficiency. For example, through the software, it is possible to monitor the operating status of the equipment and printing progress in real time, and streamline production tasks to avoid production bottlenecks.

Evaluate the ease of use, complete features, and compatibility of the software with the equipment:

Ease of use:

The operating interface of the software should be concise and easy to use. It should have an intuitive graphical interface and clear operating procedures, so that even non-professional technicians can quickly master it.

Ease of use can be evaluated by trying the software or watching a demo video of the software in action. For example, some software uses a guided process that allows users to follow step-by-step instructions to complete the entire sand 3d printing process.

Complete features:

Check whether the software has the above basic functions, such as model processing, printing parameter setting, production process management, and whether it has some special features, such as automatic optimization algorithm, remote control, etc.

The more complete the function, the higher the applicability and flexibility of the equipment. For example, some software has an intelligent optimization algorithm, which can automatically adjust the printing parameters according to the shape and structure of the casting to improve the printing efficiency and quality.

Compatibility:

Ensure that the software has good compatibility with the equipment and can control the printing equipment stably. Also, consider the software’s compatibility with other design software (e.g. CAD software) for smooth model import and processing.

You can check the software’s technical documentation or consult the manufacturer to find out what file formats and software interfaces it supports. For example, some software supports common file formats such as STL, OBJ, etc. and can work seamlessly with most CAD software.

7. Cost and return on investment analysis of 3d sand printer

7.1 Equipment purchase costs

Price range of different brands and configurations:

The price of sand 3D printers varies depending on the brand, technology level, printing size, precision and other factors. In general, the equipment price of European and American brands is relatively high, which can reach millions or even tens of millions of dollars; the equipment price of Chinese brands is relatively low, which can range from several hundred thousand to millions of dollars depending on different configurations.

For example, some high-end European and American equipment has advanced technology and excellent performance, but the price is very expensive; and some equipment of emerging Chinese brands have a more favorable price-performance ratio, such as Kocel, this brand is more famous in China, the equipment is very cost-effective, while Kocel operates a lot of foundries itself, and also provides equipment for dozens of foundry enterprises in China, it can be said that the market has been strictly tested, is a very good choice.

7.2 Analysis of the reasons for price difference:

Technology level:

Advanced printing technology, high-precision control system, stable mechanical structure, etc. will increase the cost of equipment. For example, equipment with laser sintering technology is generally more expensive than equipment with conventional binder jetting technology, because laser sintering technology has higher precision and better sand strength.

Brand influence:

Well-known brands often invest more in R&D, production and after-sales service, and their brand value is also reflected in the price of the equipment.

Some brands have many years of experience in the industry and good reputation, and can often provide more reliable equipment and better service, but the price is also relatively high.

After-sales service:

A perfect after-sales service system, including equipment installation and commissioning, training, maintenance, technical support, etc., will increase the operating cost of the manufacturer, which is reflected in the price of the equipment. Some manufacturers provide 24-hour online technical support, quick response maintenance service, etc., which will have an impact on the price.

7.3 Operating costs

7.3.1 Consumables cost:

Sand:

The sand used in sand 3D printers generally needs to meet certain requirements for grain size, shape and strength. The prices of different quality sands are different and fluctuate according to market supply and demand. For example, some special sands with high strength and low dust may be relatively expensive, but can improve the quality of the sand pattern and printing results.

Binder:

Binders are important materials that bind sand together to form sand patterns, and their prices can also affect operating costs. Different types of binders have different performance and prices, and need to be selected according to actual needs. At the same time, the amount of binder will also affect the cost, and some advanced printing technologies can reduce the amount of binder used to reduce costs.

Energy consumption cost:

The equipment will consume electricity during operation, its energy consumption cost is related to the equipment power, running time, electricity price and other factors. When selecting equipment, you can focus on the energy efficiency ratio of the equipment and choose energy-saving equipment. For example, some equipment uses advanced energy-saving technology to reduce energy consumption while ensuring print quality. High-power equipment usually consumes more energy per unit time, and if the equipment operates continuously for a long time, the energy consumption cost will increase significantly. And the difference in electricity prices in different regions will also affect the cost, such as industrial electricity concentration may have certain preferential policies on electricity prices, these factors need to be taken into account to accurately assess the energy cost.

7.3.2 Equipment maintenance costs:

Regular equipment maintenance and repair is necessary to ensure the normal operation of the equipment, and also incurs certain costs. This includes the cost of replacing wear parts, cleaning equipment, and calibration.

Some manufacturers will provide equipment maintenance service packages, which can be selected by the foundry according to their own situation. At the same time, the reliability and stability of the equipment will also affect the maintenance cost, and the maintenance cost of equipment with low failure rate is relatively low. For example, some equipment uses high-quality components and advanced design, which reduces the frequency of replacing wear parts and reduces maintenance costs.

7.4 Return on Investment Evaluation

7.4.1 Cost Savings Analysis:

Mold Cost Savings:

As mentioned earlier, the cost of mold making in traditional casting processes is very high, while 3D sand printing can significantly reduce this cost by not requiring physical mold production.

Mold cost savings can be assessed by calculating the difference between the cost of traditional mold making and the cost of 3D printing sand molds. For example, a complex casting can cost tens of thousands of dollars to make a mold, while 3D printed sand molds can reduce that cost by more than 80%.

Labor Cost Savings:

The high level of automation of 3D printing reduces the dependence on labor. Labor cost savings can be calculated by comparing the quantity and cost of labor in a traditional process with the labor requirements with 3D printing.

For example, a traditional molding line may require dozens of workers to make molds, mold forming, etc., while with 3D printers, only a few operators may be needed to monitor and maintain the equipment, reducing labor costs by about 50%.

Material cost savings:

Material costs can be reduced by precisely controlling the amount of material used and improving material utilization.

For example, while traditional molding processes can generate a large amount of waste sand and scrap, 3D printing can reduce waste by precisely controlling the use of materials based on the model. At the same time, some 3D printed materials can be recycled, further reducing costs.

7.4.2 Increased efficiency leads to increased revenue:

Reduced cycle time:

Sand 3D printers can significantly shorten product development and manufacturing cycles. For products that need to be brought to market quickly, early delivery can lead to higher market prices and competitive advantages.

The value of increased efficiency can be assessed by calculating the additional revenue generated by delivering products ahead of schedule. For example, by adopting 3D sand printing technology, an auto parts foundry shortened the development cycle of a new product from 6 months to 2 months, entered the market ahead of schedule, and gained higher market share and sales revenue.

7.4.3 Increased production capacity:

Efficient equipment and rapid prototyping capabilities can increase the production capacity of the factory, thereby increasing sales revenue. Based on the factory’s production plan and market demand, the corresponding increase in production capacity and sales revenue can be predicted.

For example, if a foundry is producing 1,000 castings per month and the introduction of a sand 3D printer increases capacity to 1,500 castings and assuming a profit of $100 per casting, the additional profit would be $50,000 per month.

7.4.4 Calculating Return on Investment:

The feasibility of an investment is assessed by calculating the payback period, which takes into account the cost of the equipment, operating costs, cost savings, and increased revenue.

The payback period is the time from when the equipment is put into use until the entire investment is recovered. For example, assuming the cost of purchasing a sand 3D printer is $2 million and the cost savings and increased revenue total $800,000 per year, the payback period would be approximately 2.5 years.

The potential impact of market changes, technology updates and other factors on the payback period also needs to be considered for a more accurate assessment.

7.5 Market research and brand selection

Collecting Market Information

Industry Exhibitions:

Participating in domestic and foreign foundry exhibitions is an important way to collect market information on 3D sand printers. At the exhibition, you can directly contact many equipment manufacturers and learn about their latest products and technologies.

At the exhibition, you can have in-depth discussions with the manufacturer’s technical staff and sales staff, and get detailed product information and quotations. At the same time, you can also observe the live demonstration of the equipment, visualize the performance of the equipment and the operating process.

For example, in some major international foundry exhibitions, there will be famous manufacturers from all over the world displaying their latest equipment and technologies, providing foundries with a wide range of choices.

Professional Websites:

There are many professional casting equipment websites and industry forums, which gather a large amount of equipment information, user reviews and technical articles. By browsing these websites, you can understand the characteristics of different equipment brands, user feedback and market trends.

Some websites also provide equipment comparison and selection tools to help users choose more suitable equipment for themselves.

For example, on some professional websites, you can find detailed parameter comparisons of different brands of sand 3D printers and actual user reviews, providing reference for purchasing decisions.

User forums:

Join forums or user communities in the casting industry to exchange experiences with other foundry users. These users often share their actual experiences of using different equipment, the problems encountered and the solutions.

Their experience and advice for new users are invaluable, and can help avoid some common mistakes and pitfalls. For example, on some forums, users will share information about the actual use of the equipment and the quality of after-sales service, which will provide reference for other users when choosing equipment.

Evaluate brand reputation

Manufacturer qualifications:

Check the quality certificates and honorary awards of the equipment manufacturer to understand their status and influence in the industry. For example, some manufacturers have national high-tech enterprise certification, ISO quality management system certification, etc.

These qualifications demonstrate the manufacturer’s capabilities in technology research and development, production management and other aspects. Titles and awards, such as industry science and technology innovation awards, excellent product awards, etc., also reflect the manufacturer’s products in terms of recognized technology and quality.

Manufacturing experience:

Manufacturers with rich manufacturing experience are generally more secure in terms of product quality and after-sales service. You can find out how long the manufacturer has been engaged in the production of sand 3D printers, the scale of production, and previous project experience.

A manufacturer that has been in the industry for many years and has provided equipment and solutions to many foundries is often more trustworthy. For example, some manufacturers have been in the casting industry for decades, have accumulated a lot of experience, and can provide personalized solutions according to the needs of different foundries.

Technology R & D strength:

Focus on the manufacturer’s technology R & D investment and innovation capabilities. Advanced technology is a guarantee of the performance and quality of the equipment, the manufacturer has its own R & D team, patented technology and cooperation with scientific research institutions can be used as the basis for evaluation.

For example, some manufacturers continue to invest in R & D funds, introduce new printing technology and features to meet the changing needs of the market, such manufacturers have a more forward-looking vision of technology.

Market share and user reviews:

Understanding the market share of a brand’s equipment can reflect its popularity and competitiveness in the industry. At the same time, by checking the reviews of other users, you can get real feedback on the quality, performance and after-sales service of the equipment.

You can search online for user reviews, consult with industry experts, or directly contact other foundries to find out how they feel about using the brand’s equipment.

For example, if a brand of equipment on the market has a high market share and generally good user reviews, then that brand is excellent in all aspects.

Site survey and prototype testing

Site survey:

If conditions permit, it is recommended to visit the equipment manufacturer for a site survey. You can visit the manufacturer’s manufacturing plant, learn about the production process, quality control process, and the level of advanced production equipment.

Observe whether the manufacturer’s production management is standardized, the technical level of the staff and the working attitude. At the same time, you can also have in-depth discussions with the manufacturer’s technicians and managers to understand their technical capabilities and service perspectives.

For example, in the production workshop, you can check the equipment assembly process, the quality of parts and components, and the quality inspection stage in the production process.

Prototype testing:

This is a very important step to strive for prototype testing. Test the prototype at the manufacturer or their own factory, put the actual casting model into the equipment, observe the equipment printing process, sand quality, as well as the stability and reliability of the equipment.

Through prototype testing, you can visualize whether the equipment meets your production needs and quality requirements. During the test, pay attention to record the printing time, sand accuracy, surface quality and other important data, and compare them with the specifications provided by the manufacturer.

For example, you can prepare some representative models of complex castings for testing and observe the performance of the equipment in processing complex structures.

Remember, this is very important, if you can not visit the site temporarily, even if you have to pay the cost (the quantity is not large, generally the manufacturer will play for free, or at a cost to help you play) but also try to let the manufacturer print samples, this is the most intuitive way to understand the printing quality of the equipment.

After-sales service and technical support

After-sales service content

Equipment installation and operation:

Equipment installation and operation is the basis for ensuring the normal operation of the equipment. Excellent after-sales service should include a professional installation team to ensure that the equipment can be properly installed and initially operated and calibrated.

During the installation process, it is necessary to explain to the user the basic structure and operation method of the equipment so that the user can have an initial understanding of the equipment.

For example, the installer will arrange the installation location of the equipment according to the actual layout of the factory and production requirements, and carry out electrical and mechanical connections and debugging.

Training:

Comprehensive training services are very important for users. The training content should include equipment operation skills, software use, regular maintenance knowledge and common troubleshooting methods.

Training can be divided into on-site training and online training in two forms to meet the needs of different users.

For example, on-site training can be conducted after the equipment installation is completed, with direct guidance from professional instructors; online training can be through instructional videos, online classes and other ways to allow users to learn anytime, anywhere.

Repair and maintenance:

Timely and effective maintenance service is a guarantee for the long-term stable operation of the equipment. After-sales service should include regular equipment maintenance, such as cleaning, lubrication, inspection, etc., as well as prompt response and repair in the event of equipment failure.

The manufacturer should provide sufficient spare parts inventory to ensure that damaged parts can be replaced in a timely manner during maintenance. For example, when the equipment fails, the after-sales service team should arrive on-site within the specified time to handle the problem and repair it, minimizing the impact of equipment downtime on production.

Software Upgrade:

With the continuous development of technology, the software of the equipment also needs to be continuously upgraded and optimized. After-sales service should include regular software upgrade services to improve the performance and functions of the equipment.

Software upgrades can be performed remotely via the network or by on-site technicians to ensure the upgrade process is smooth and safe.

For example, the new software version may add some new functions, such as optimizing the printing algorithm, improving printing speed and accuracy, etc., to bring better user experience.

The importance of technical support

Solving technical problems:

During the use of the equipment, various technical problems may be encountered, such as optimizing printing parameters, improving sand quality, compatibility issues with other equipment, etc.

Professional technical support team can provide timely solutions to help users solve these problems to ensure smooth production.

For example, when encountering the problem of substandard printing accuracy, technical support staff can analyze the printing parameters, equipment status and other factors, and give corresponding adjustment recommendations to improve the printing accuracy.

Optimizing printing parameters:

Different castings and production environments may require different printing parameter settings. Technical support staff can provide optimized printing parameters.

3D printing equipment assembly workshop

Summary and recommendations

Summary of key points and considerations when purchasing

Clear needs: Before purchasing, you must have a clear understanding of the current production status of the factory, product characteristics, development plans, etc., and clarify your needs and expectations for the direction of improvement, so that you can choose the most suitable equipment for yourself.

Comprehensive evaluation of equipment features: from printing accuracy, printing size, equipment stability, software support and other aspects of the equipment to comprehensively evaluate to ensure that the performance of the equipment meets production requirements.

Consider the cost and return on investment: not only should pay attention to the cost of purchasing the equipment, but also fully consider the operating costs, cost savings and revenue increase and other factors, calculate the investment payback cycle, ensure the feasibility of investment.

Pay attention to brand reputation and after-sales service: choose a manufacturer with good brand reputation, rich production experience and strong technical research and development capabilities, and ensure that the manufacturer can provide perfect after-sales service and technical support.

Encourage wise decision-making

Traditional foundries should be willing to experiment with new technologies and equipment in the face of equipment innovation and technology upgrades. As an advanced technology, sand 3D printers can bring great changes and improvements to foundries. However, when making a purchase decision, we should consider all the factors, conduct sufficient market research and analysis, and communicate and discuss in depth with the manufacturer. There are several industrial sand 3D printers to choose from.

We hope that managers of traditional foundries can make wise purchasing decisions based on this purchasing guide, taking into account the actual situation of their factories, and recommend suitable 3D sand printers to them, so as to enhance the competitiveness of their factories, realize sustainable development, seize the first opportunity in the wave of digital transformation, and breathe new life into the development of the foundry industry.

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