Identical remanufacturing from an existing part

3D Scan of the Existing Part: Precise Digitization

The first crucial step consists of meticulously preparing and scanning the original part. Its surface is cleaned to ensure optimal capture.

The use of a 3D scanner enables ultra-precise acquisition of the smallest details: complex volumes, delicate reliefs, fine moldings, and even wear marks or minor defects.

• Faithful capture of shapes and textures
• Generation of a high-resolution point cloud
• Respect for the original geometry, including its history

Objective: To obtain an exact digital replica, serving as a foundation for reproduction.

Reverse Engineering: From Point Cloud to Optimized Model

The point cloud obtained during the scan is then transferred to an engineering firm. This is where reverse engineering truly takes on its full meaning. The raw digital model is reworked with Computer-Aided Design (CAD) software.

• Cleaning and optimization of the point cloud.
• Precise reconstruction of surfaces for a solid 3D model.
• Correction of imperfections due to wear or breakage.
• Technical adaptation for the foundry (draft angles, extra thicknesses required for demolding, consideration of material shrinkage).

Result: A 3D model visually faithful to the original, but technically ready for the casting process.

Creation of the Physical Model

This step can be eliminated thanks to our new sand mold printing technology, without the need for tooling.

From the optimized 3D file, a model, also called physical tooling, is manufactured.

Before creating the mold itself, tooling is manufactured. It is the "exact copy" of the final part:

• The Parting Line: separation line between the upper and lower parts of the mold. It must be placed intelligently to allow the model to be removed without tearing the sand.
• Risers: reservoirs of liquid metal. As the metal contracts upon cooling, the riser "feeds" metal to the part to prevent holes (shrinkage cavities).
• The Gating System: a network of channels that guides the liquid metal towards the mold cavity. It must be designed so that the metal enters without turbulence.

Result: A 3D model visually faithful to the original, but technically ready for the casting process.

Sand Casting – Taking an Impression in Sand

The model is then carefully positioned in a foundry flask.

The molding sand is compacted around it, creating a perfect negative impression.

Once the tooling is ready, it is used to create the void (the cavity) into which the metal will be poured.

Sand casting: a mixture of sand and binder (glue) is packed around the pattern.

Demolding the model: the mold is opened, the physical model is removed, and a perfect "hole" (or cavity) in the shape of the part remains.

Iron Casting: The Magic of Transformation

The moment of pouring is the climax of this process. The molten metal is heated to extreme temperatures in a furnace, reaching its perfect liquid state. The foundry workers, with millimeter precision, then pour this incandescent metal into the previously prepared sand mold.

It is during this stage that the raw material takes the exact and detailed form of the future bench leg, respecting every nuance of the original 3D model.

• Molten metal heated to a high temperature for optimal fluidity.
• Controlled pouring in the mold channels.
• Complete and homogeneous filling of the impressions.
• Slow and controlled cooling to avoid internal stresses.

Demolding and Finishing: Revealing the Work

Once the metal has cooled and solidified, the part is released from its mold. This step, called shakeout (or demolding), involves breaking the sand mold to reveal the cast part.

The process continues with a series of essential finishing operations:

The finishing stages

• Demolding: careful breaking of the mold and retrieval of the part.
• Fettling: cutting of casting gates and excess risers.
• Smoothing: manual or mechanical deburring to smooth surfaces and eliminate imperfections.
• Quality control: A rigorous visual and dimensional check is carried out to guarantee perfect conformity to the original.