Mega-Format Binder Jetting 3D Sand Mold Printers
Prepare your foundry's largest and most complex castings for production in hours — directly from CAD data, with no pattern or core box. AJS2500 at 800 L/h and AJS4000 at 1500 L/h: mega-scale Binder Jetting is now available in Türkiye.
Mega-Scale Binder Jetting
In conventional foundries, tooling for large parts takes weeks — every design revision means a new pattern. AJS2500 and AJS4000 eliminate this: casting-ready sand molds emerge from a CAD file in hours, with no physical tooling required.
Model Comparison
Your annual production volume and maximum part size determine the right model. Contact our team for a project-specific feasibility analysis.
| Parameter | AJS2500 | AJS4000 |
|---|---|---|
| Max. Build Volume (L×W×H) | 2500 × 1500 × 1000 mm | 4000 × 2500 × 1500 mm |
| Build Rate | 800 L/h | 1500 L/h |
| Layer Time | ~14 s/layer | ~20 s/layer |
| Layer Thickness | 0.2 – 0.8 mm | 0.2 – 0.8 mm |
| Accuracy | ±0.4 mm | ±0.4 mm |
| Machine Weight | ~30 t | ~65 t |
| Automation | AGV/RGV compatible | AGV/RGV compatible |
| Compatible Sand | Silica, Ceramic, Chromite, Zircon | Silica, Ceramic, Chromite, Zircon |
| Compatible Binder | Furan, Phenolic, Inorganic | Furan, Phenolic, Inorganic |
| Sand Reclamation | Automatic + optional thermal | Automatic + optional thermal |
Comparison
The time, cost and flexibility advantages of digital production for mega-scale cast parts.
| Criterion | Conventional Sand Mold | KOCEL 3D Binder Jetting |
|---|---|---|
| Production Time | Weeks–months for pattern/core box | Ready mold within days from a digital file |
| Design Freedom | Serious geometry constraints | Unlimited — undercuts, internal channels, complex geometry |
| Core Production | Separate core box and assembly required | Core and mold in a single print, one piece |
| Revision Cost | New pattern cost per revision | Instant revisions, zero additional cost |
| Surface Quality | Low, heavy finishing required | Better surface quality than conventional |
| Prototype to Series | Very high unit cost in small batches | Prototype to series with the same system |
| Storage | Pattern warehouse, space and maintenance cost | No patterns — only a digital file is stored |
| Waste Management | High chemical waste | Zero liquid waste, closed-loop sand reclamation |
| Cost Advantage | Reference | 30–50% savings at 1,000–5,000 castings/year |
Sand & Binder Options
Sand and binder are selected by casting metal and quality requirement; different resins can even be used per region within the same print.
| Sand Type | Typical Application |
|---|---|
| Quartz / Silica Sand | General-purpose castings (iron, steel, aluminium) |
| Ceramic Sand | High-temperature castings (titanium, nickel superalloys) |
| Chromite Sand | Stainless steel and heavy castings (low thermal expansion) |
| Zircon Sand | Precision casting, applications requiring fine surface quality |
| Binder (Resin) | Properties & Advantages |
|---|---|
| Furan Resin | High strength, general purpose, low cost — common in iron, steel and alloy castings |
| Phenolic Resin | Better thermal stability, low gas emission — preferred for aluminium and magnesium castings |
| Inorganic Binder | Zero VOC emission, fully compliant with environmental regulations, zero liquid waste — ideal for clean, sustainable production |
Applications
Frequently Asked Questions
No. Beyond build volume, the AJS4000 features a reinforced one-piece machined frame (~65 t) engineered for ultra-large parts, different floor loading requirements, a higher-capacity sand-laying system, and an optimized printhead motion profile reaching 1,500 L/h. Your annual production volume and maximum part size determine the right choice — contact our team for a project-specific feasibility study.
Automotive engine blocks, transmission housings, aerospace structural castings, wind and gas turbine casings, heavy machinery chassis parts, large pump and valve bodies, and ship propeller hubs — any large-format, geometrically complex casting that benefits from tooling-free production. At 1,000–5,000 castings per year, cost savings of 30–50% versus conventional tooling are typical.
Yes. The system reclaims used sand at up to 90% through sieving, filtering, and optional thermal regeneration. With inorganic binder, no cleaning agent is required — zero liquid waste discharge and zero VOC emissions. The entire system complies fully with EU Environmental Regulations and ISO 14001.
The KOCEL AJS Series is optimized for industrial foundry conditions. Precision linear guides and the printhead system are protected by high-grade dust- and heat-resistant seals. An automatic lubrication system minimizes manual maintenance. Holiday mode enables unattended overnight and weekend operation, while remote monitoring provides real-time status visibility.
Conventional sand casting requires a pattern and core box for every new geometry — the tooling cycle takes weeks and repeats with every revision. With KOCEL AJS, the path from digital CAD to casting-ready sand mold is measured in hours. Design revisions are free, and multiple geometries can be printed simultaneously in the same job box.
Quote and Information
Reach our expert team for pre-sales technical consulting, feasibility reports, demo requests, or pricing. 25 years of experience at your side.
