Linear Motion Technology
Heavyweights from the 3D Printer: voxeljet and Linear Motion Technology from Bosch Rexroth Give Casting a New Dimension
Sand molds for giants weighing up to 60 tons – that is what the world's largest industrial 3D printer can achieve. It was developed and built by the 3D printing systems specialist voxeljet. The new manufacturing technology of the VX9000 large-format sand binder jetting 3D printer aims, among other things, to reduce production times and costs in the wind and hydro power sectors. A particular challenge was the precise positioning of the print heads as well as stable and highly accurate motion control. For this, voxeljet relies on linear motion technology from Bosch Rexroth.
Sand molds are particularly suitable for producing large and complex castings. These include machine components, parts for the wind and hydro power industries, automotive and aircraft components, as well as works of art and sculptures. A major advantage is the variety of materials, as different metal alloys can be processed without difficulty.
voxeljet has integrated these strengths into a gigantic 3D printer. The company was selected by GE Vernova as a partner to develop and commercialize a large-format printer utilizing sand binder jetting technology. The VX9000 is intended to provide new momentum for the local foundry industry in the USA in the hydro and wind energy sectors.
(image source: voxeljet)
Among other things, sand molds are being produced for GE Vernova in the USA to cast the main components of wind turbine generators – with the goal of reducing costs in the wind and hydro power industries. Furthermore, 3D printing is also to be used to test opportunities for lightweight design and functional integration for multi-ton castings. In this way, resource consumption can be reduced and assembly work simplified. The joint project between voxeljet, GE, and the Fraunhofer Institute IGCV is supported by the project management agency Projektträger Jülich and the German Federal Ministry for Economic Affairs and Climate Action.
(image source: voxeljet)
Revolution: Printer Shapes Ton-Heavy Castings
The VX9000 3D printer is capable of producing sand molds for castings weighing between 10 and over 60 tons. In large-scale casting, this will make geometries feasible that were previously unthinkable, enabling enormous savings potential in the design and weight of parts for wind turbines. It operates with recycled molding sand, just like the sand used in traditional molding processes, thereby enabling cost-effective and reliable additive manufacturing in the foundry environment.
Alexander Kudernatsch, Director Services at voxeljet, explains: "Our VX9000 is currently the largest 3D printer for foundry products in use worldwide. Never before has a system of this size and with this build speed been designed and built. It goes far beyond the previous fields of application and scale of 3D printers. To implement it, we brought Bosch Rexroth on board. Crucial criteria for this decision were the long-standing cooperation, the high quality of the linear motion technology products, and Bosch Rexroth’s comprehensive understanding of 3D printing requirements."
As if cast from a single mold: Linear Modules Interlock with Precision
"A project of this dimension is also something special for us," says Uwe Schulz, Account Development Manager at Bosch Rexroth. "The project planning phase required the implementation of an 8-meter-long linear axis with 7 table parts, as well as a precise offset of the print heads. This is the only way to achieve a seamless and high-quality print image. Our highly stable and low-wear linear motion components form the foundation for the required accuracy."
The VX9000 utilizes roller rail systems, ball screw drives, and linear modules with ball rail systems and tooth belt drives (MKR) from Bosch Rexroth. These high-performance components are used for the precise height positioning of the axis assemblies. The ball screw drives used have already proven themselves at voxeljet in a different design – in the VX4000 3D printer. Linear modules are used to position the print head precisely. These, too, are already reliably in use in a similar form in other systems at voxeljet.
(image source: voxeljet)
"While we are already producing molds for castings weighing several tons with the VX4000, for example for the pump industry, the VX9000 takes the whole thing to a new level. Bosch Rexroth's profile rail guides, ball screw drives, and linear modules possess a unique level of precision and load capacity that is indispensable for use in the large-scale production of castings," says Alexander Kudernatsch.
(image source: voxeljet)
Sustainability as a Driver of Innovation
The innovative approach of the VX9000, which enables fully additive manufacturing using recycled molding sand, opens up completely new perspectives for foundry technology. In addition to cost advantages, this technology also contributes significantly to ecological improvements. The goal is to produce molded parts with reliable casting behavior while ensuring the economical use of standard recyclates in the foundry environment – a decisive step towards more sustainable and resource-saving production.
"Ultimately, it is about paving the way for clean energy production. The project in the USA is a blueprint for various markets that are increasingly relying on sustainable manufacturing technologies," emphasizes Uwe Schulz.
Alexander Kudernatsch adds: "The linear motion specialists at Bosch Rexroth bring a deep understanding of our processes, which has helped us enormously in the further development of the VX9000. This close collaboration enables us to specifically address and further drive future requirements regarding speed, precision, and, above all, sustainability."
Contact Person: Uwe Schulz
Position: Account Development Manager
Phone: +49 7303 9053 907
Cell: +49 174 3173793
Uwe Schulz
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