Digital additive technologies

Production of high-tech castings with aluminum and magnesium alloys based on the modular manufacturing facilities with the use of digital additive technologies.

About company

  • Advantages
  • Concept
  • Objectives
  • Preproduction time
    The reduced time for production preparation and manufacturing of individual samples, small series of castings for the design and development activities by 5-8 times.
    Labour intensity
    Labour savings in the serial production of castings by 3–5 times due to no need for manufacturing any shape-generating moulding tools.
    Weight castings
    Decrease in the weight of body castings by 20-40% is achieved by the increased geometric precision of casting.
    Casting precision
    Increased geometric precision of shaped castings and reduced allowance for processing greatly reduce the amount of product machining
    Flexible changeover
    Flexible changeover of production capacities through the development of new products without the production process retooling at any stage of design and development projects and series production.

    of the production of high-tech castings of aluminum and magnesium alloys based on modular manufacturing facilities with digital additive technologies.

    The relevance of this project stems from the need to ensure the accelerated development of new products, prepare production and make competitive products that meet international standards.

    The target customers and prospective consumers are the aerospace, automotive, nuclear power engineering, mechanical engineering and defence industries.

    The use of modular engineering and manufacturing facilities can help quickly readjust to new products. The established digital foundry engineering and manufacturing facilities can be easily integrated into the production process chain of an operating company according to the customer’s technical programme.

    Creation of a modern digital foundry based on modular engineering and manufacturing facilities to provide customers with the casting body blocks of aluminum and magnesium alloys.

    The planned annual output of casting aluminum and magnesium alloys is up to 200 tons per year.

    Promotion of innovations in the digital additive technologies in Russia.

    Technologies

    Sand and polymer casting moulds

    The use of the 3D printing technology enables the production of accurate and durable sand moulds and rods using STL files, which are generated directly according to the mathematical models of CAD/CAM/CAE design and engineering analysis systems, as the input data for process facilities.

    An additive mould manufacturing technology reduces the time for preparation to the production from 3-8 months to 1-1.5 months as well as it reduces the number of mould components.

    Casting

    Application of low-pressure casting allows to obtain high-quality castings of the aluminum and magnesium alloys.

    An alloy is fed from the furnace to the casting mould by means of a centrifugal pump. By varying different parameters, it is possible to adjust the mould filling rate and alloy temperature distribution considering the configuration of castings.

    The key advantages of low-pressure casting are the high density of castings and the high level of automation.

    Manufacturing

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    When designing parts, castings and moulds used are state-of-the-art information technologies, design and technological engineering analysis, computer-aided metal casting simulation. The absence of any limitations associated with the use of forming devices makes it possible for you to design and manufacture the rods and moulds of any difficulty and configuration, with undercuts and without slopes.

    Additive technologies allow prompt optimisation and adjustment of the design of castings, gating and supply systems and sand casting moulds directly in the manufacturing process as well as the flexible readjustment of production capacities through the development of new products without any retooling the production process.

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    Address 123317, Moscow, Presnenskaya Embankment Building 8, page 1 Contact Number +7 (495) 745-01-77 Telephone / fax +7 (495) 745-01-77 E-mail info@digital-at.ru