AJS2500 & AJS4000

Binder Jetting

AJS2500 / AJS4000

800–1500 L/h

Series Production

±0.4 mm

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.

Request a Quote → Technical Specifications

KOCEL AJS2500 AJS4000 Mega Binder Jetting Printer

KOCEL AJS2500 AJS4000 Dual-Set Binder Jetting System

Mega-Scale Binder Jetting

Beyond the Limits of Conventional Casting

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.

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Bidirectional High-Speed Printing

AJS2500 achieves ~14 s/layer, AJS4000 ~20 s/layer. The Jump White algorithm skips binder-free zones, reducing total build time significantly on every job.

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24/7 Unattended Operation

AGV/RGV automated jobbox transfer, holiday mode, and remote monitoring keep the system running nights and weekends without operator presence.

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Zero Waste & Sustainable Production

With inorganic binder, zero VOC emissions and zero liquid waste discharge. Sand is reclaimed at up to 90% via thermal regeneration. Full compliance with EU environmental regulations and ISO 14001.

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Selective Regional Strength Optimization

Binder concentration can vary across different zones of the same mold to match casting stress patterns. Critical regions get higher strength while material consumption drops elsewhere.

Technical Data

AJS2500 & AJS4000 - Technical Specifications

Parameter	Value
Max. Build Volume (L×W×H)	AJS2500: 2500 × 1500 × 1000 mm · AJS4000: 4000 × 2500 × 1500 mm
Build Rate	AJS2500: 800 L/h · AJS4000: 1500 L/h
Layer Time	AJS2500: ~14 s/layer · AJS4000: ~20 s/layer
Layer Thickness	0.2 – 0.8 mm
Accuracy	±0.4 mm
Machine Weight	AJS2500: ~30 t · AJS4000: ~65 t
Automation	AGV/RGV compatible
Compatible Sand	Silica, Ceramic, Chromite, Zircon
Compatible Binder	Furan, Phenolic, Inorganic
Sand Reclamation	Automatic + optional thermal

Frequently Asked Questions

What You Wonder About

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.

AJS2500 & AJS4000

Beyond the Limits of Conventional Casting

AJS2500 & AJS4000 - Technical Specifications

What You Wonder About

Is the difference between AJS2500 and AJS4000 just the build volume?

Which sectors and part types are these systems designed for?

Can used sand be reclaimed? How is environmental compliance achieved?

How is system reliability maintained in a demanding foundry environment?

What is the core difference between Binder Jetting and conventional sand casting?

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