Published on Thu Jul 23 2020 12:06:39 GMT+0000 (Coordinated Universal Time) by Alex

The Voxeljet VX2000: A Deep Dive into Large-Format Sand Printing

The Voxeljet VX2000 is a powerhouse in the world of binder jetting 3D printers, specifically designed for large-format sand casting molds and cores. It’s a workhorse for industries like automotive, aerospace, and foundries, enabling the rapid creation of complex geometries impossible or impractical to achieve with traditional methods. This article explores the VX2000 in detail, covering its specifications, operational advice, and a thorough evaluation of its core features.

Unveiling the VX2000: Technical Specifications and Capabilities

The VX2000 isn’t your typical desktop 3D printer. It’s a sophisticated industrial machine, and its specifications reflect that:

• Technology: Binder Jetting
• Build Volume: 2000 x 1000 x 1000 mm (78.7 x 39.4 x 39.4 inches) - This massive build volume is its primary strength.
• Layer Thickness: Typically adjustable between 150-400 µm (0.15 - 0.4 mm), depending on the specific application and desired resolution.
• Materials: Primarily specialized silica sands or ceramic powders, bound together by a chemical binder. The specific sand type affects surface finish and thermal behavior.
• Binder: Furan resin-based binders are common, providing the necessary strength for mold handling. Other binders can be used depending on application requirements.
• Print Heads: Multiple high-precision print heads ensure even binder distribution across the large print bed.
• Print Speed: Variable, dependent on layer thickness, material, and part complexity. Generally, it can print a full build volume in several days.
• Resolution: While not as precise as some polymer printers, the resolution is sufficient for casting applications, typically around 300 dpi.
• Machine Dimensions: Significantly larger than the build volume, requiring considerable floor space. Exact dimensions vary depending on the specific configuration.
• Power Requirements: High, typically requiring three-phase power.
• Software: Voxeljet’s proprietary software suite, designed for job preparation, slicing, machine control, and monitoring.
• Post-Processing: Depowdering (removing unbound sand) is essential. Depending on the application, infiltration with a molten metal (e.g., aluminum or bronze) might be performed to enhance strength and density.

Maximizing Performance: Usage Tips and Best Practices

Operating a VX2000 effectively requires expertise and attention to detail. Here are some tips to ensure optimal results:

• Material Selection: Carefully choose the sand type and binder based on the specific metal being cast and the required surface finish of the final part. Consider thermal conductivity, grain size, and binder reactivity.
• Job Preparation: Meticulously plan the part orientation within the build volume to optimize packing density and minimize support structures. Proper nesting is critical for efficient use of the large build space.
• Slicing Parameters: Experiment with layer thickness and binder saturation settings to achieve the desired balance between print speed, resolution, and part strength.
• Binder Management: Maintaining the correct binder viscosity and temperature is crucial for consistent printing. Regularly check and calibrate the binder delivery system.
• Depowdering Techniques: Use appropriate depowdering equipment, such as compressed air nozzles or specialized brushing tools, to remove excess sand effectively without damaging the printed part.
• Environmental Control: Maintaining a controlled environment with consistent temperature and humidity can minimize warping and improve print quality.
• Regular Maintenance: Adhere to the recommended maintenance schedule, including cleaning print heads, replacing filters, and inspecting mechanical components, to ensure reliable operation.
• Operator Training: Provide thorough training for operators on machine operation, material handling, software usage, and safety procedures. The VX2000 is a complex machine, and skilled operators are essential for success.
• Support Structure Design: While binder jetting allows for complex geometries, intelligent support structure design is still important for preventing collapse and ensuring accurate part dimensions, especially for overhanging features.
• Simulation: Employ casting simulation software to predict potential issues such as shrinkage or porosity, allowing for design adjustments before printing.

VX2000 Performance Metrics

Here’s an assessment of the Voxeljet VX2000 across key performance categories, graded on a scale of 1 to 10:

• Print Quality: 8/10 - Excellent for casting applications, achieving smooth surfaces and dimensional accuracy suitable for metal parts.
• Build Volume: 10/10 - Unmatched large-format capabilities, making it ideal for producing large or numerous smaller parts simultaneously.
• Printing Speed: 7/10 - Relatively fast for its size, but slower compared to smaller polymer-based printers.
• Material Compatibility: 6/10 - Primarily limited to sand and ceramic powders for casting, although some material advancements are ongoing.
• Bed Adhesion & Leveling: 9/10 - Bed adhesion isn’t as critical with binder jetting, but precise leveling is essential for consistent layer deposition. Automatic leveling systems contribute to ease of use.
• Reliability: 8/10 - A robust industrial machine, but regular maintenance is crucial for consistent performance.
• Ease of Use: 6/10 - Requires trained operators due to its complexity and specialized processes.
• Firmware and Software: 7/10 - Voxeljet’s software is powerful but has a learning curve. Continuous improvements are being implemented.
• Connectivity Options: 7/10 - Standard network connectivity for remote monitoring and control.
• Build Quality & Durability: 9/10 - Built to withstand industrial environments and deliver years of reliable service.
• Noise Level: 6/10 - Relatively noisy due to the operation of print heads and material handling systems.
• Maintenance Requirements: 5/10 - High maintenance requirements due to the nature of sand printing. Regular cleaning and component replacement are necessary.
• Customer Support: 7/10 - Voxeljet provides comprehensive support, including training, maintenance contracts, and technical assistance.
• Upgradeability: 6/10 - Limited upgrade options, as the machine is designed for specific materials and applications.
• Price to Performance Ratio: 7/10 - High initial investment, but the large build volume and specialized capabilities can justify the cost for certain applications.

Average Score: 7.2/10

Conclusion: A Specialized Tool for Large-Scale Sand Casting

The Voxeljet VX2000 is a specialized 3D printing system designed for demanding sand casting applications. Its massive build volume, combined with the binder jetting process, enables the rapid creation of complex molds and cores for metal casting. While it requires a significant investment and skilled operators, its unique capabilities make it a valuable asset for industries seeking to accelerate product development and optimize casting processes. Proper material selection, careful job preparation, and diligent maintenance are crucial for maximizing the VX2000’s performance and realizing its full potential.

Written by Alex