Cast part produced from a sand 3D-printed mould
Sand 3D printing

3D Prototypes Foundry

From CAD design to the manufacture of cast prototypes in record time. Scanning, modelling and sand 3D printing serving cast iron, bronze and aluminium.

Moulds and cores printed up to 1800 × 1000 × 700 mm.

Send us your 3D file
< 7 hours
Mould / core manufacturing
savings > €2,000
No traditional tooling
1800 × 1000 × 700 mm
Max. print volume

Technical capabilities

The key figures for scoping a prototype, a part reconstruction or a small production run.

From the first sketch to the rendered image

Our models are created on our CAD workstations, in both 2D and 3D — from basic primitives (lines, arcs, volumes) to complex, structured, parametric objects. 3D models let us validate assemblies, optimise materials, fine-tune the best production techniques and provide manufacturing drawings for machined or cast components.

  • Cast iron / bronze / aluminium foundry
  • Coremaking
  • Industrial part reconstruction
  • Machining
  • Industrial and artistic part reconstruction
  • Speed: 1 to 2 weeks for a raw part
  • Cost-effective: no upfront tooling required
  • Simplicity: mould and cores made from a single 3D file
3D CAD modelling of a cast part on a design workstation

Fast turnaround

Moulds and cores manufactured and delivered in hours or days, compared to several weeks with traditional methods.

Significant cost reduction

Eliminates the costs of traditional patterns, tooling and core boxes.

Exceptional design freedom

Production of complex geometries that are impossible to achieve with traditional methods (draft angle or parting line issues).

The 5-step process

  1. 01
    3D scanning of an existing part

    3D scanning

    Our expertise combined with modern 3D scanners allows us to digitally recreate any part.

  2. 02
    CAD design optimised for casting

    CAD design

    Modelling optimised for manufacturing and seamless integration into your production line.

  3. 03
    3D printing of a sand mould

    Sand 3D printing

    Fast production with no tooling and high precision.

  4. 04
    3D-printed foundry core

    3D coremaking

    Complex cores manufactured in hours, ideal for rapid prototyping.

  5. 05
    Finished part in cast iron, bronze or aluminium

    Result

    Cast iron, bronze or aluminium parts manufactured with precision and no tooling.

Examples of parts and renderings

Clear visual examples to appreciate the shapes, volumes and possibilities offered by sand 3D printing.

Artistic piece

Production of artistic pieces formerly made using the lost-wax technique.

Sculptural prototype

Manufacture of organic, detailed shapes from a digital model.

Shape optimisation

By optimising complex shapes, no material is left where it serves no purpose.

Sand 3D printing — mould produced in under 7 hours
Sand 3D printing
Traditional method — machining and manual moulding
Traditional method
3D-printed foundry core — reduced cost
3D-printed core
3D-printed foundry mould — no traditional tooling
3D-printed mould
Example of a part impossible to produce with traditional casting
Exceptional design freedom
Example of a part impossible to produce with traditional casting
Exceptional design freedom
Part previously made in several sections and then assembled
Elimination of assembly steps
Part produced as a single piece
Elimination of assembly steps

Technical specifications

Cast-iron foundry since 1850 · ISO 9001 · Certified quality

  • Materials: cast iron, bronze, aluminium
  • Max. print dimensions: 1800 × 1000 × 700 mm
  • Lead time: moulds and cores in a few hours to a few days
mould < €50
Sand 3D printing
core < €15
3D coremaking
1 to 10 parts
Small runs

Moulds and cores printed up to 1800 × 1000 × 700 mm.

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    3D Prototypes Foundry | Birdie Foundry