Reverse Engineering and Topology Optimization with 3D Sand Printing

This case study presents the successful application of 3D sand printing, topology optimization, and direct cooling techniques by the Austrian Foundry Institute (ÖGI) to replace a welded steel agricultural machine construction with a topology optimized casting within one week. The initiative was part of the 'Inno-Up' research project, which involved collaboration among 22 organizations, including foundries and research institutes. The project aimed to test the integration of digital technologies in the production of cast components while utilizing the design flexibility offered by casting methods. The optimization process included analyzing the initial welded structure, conducting FEM calculations, and defining specifications for weight reduction and material properties. The final optimized component weighed 2.5 kg, achieving a 36% reduction in weight compared to the original. The study highlights the potential benefits of additive manufacturing in terms of resource efficiency and emissions reduction throughout the product lifecycle.