First voxeljet VX9000 castings completed at Baettr foundry

The VX9000 sand binder jetting 3D printer, developed through a strategic collaboration between voxeljet, GE Vernova, and Fraunhofer IGCV, has been used for the first successful casting of large-scale sand molds at Baettr Foundry. This milestone underscores the transformative potential of the world’s largest binder jet 3D printer as it enters the next phase of clean energy manufacturing. Designed by voxeljet specifically for large-format applications in wind and hydro energy sectors, the VX9000 is a de facto game changer.

The successful casting of benchmark molds—each extending up to 9.5 meters—demonstrates the VX9000’s readiness for real-world industrial use. These castings maintain dimensional accuracy within expected ranges, a critical factor in high-precision applications such as turbine component production. Even more significantly, the pouring process was conducted under authentic foundry conditions, mimicking real-world manufacturing environments and validating the robustness of the VX9000 system.

The initial observations from this trial—regarding workflow, handling, and performance—are now guiding further refinements. These learnings will be integrated into the production pipeline, streamlining the system for broader industrial adoption.

VX9000: engineered for scale and precision

Originally presented in 2021, the VX9000 has been meticulously engineered to produce near-net shape (NNS) components essential for the energy sector’s largest and most complex infrastructure. Its sheer scale allows for the printing of sand molds that will ultimately become turbine nacelles—components weighing upwards of 60 metric tons.

This cutting-edge technology has been under development as part of the U.S. Department of Energy’s Advanced Casting Cell (ACC) initiative. Backed by $14.9 million in federal funding, the ACC aims to expedite America’s transition to sustainable energy by modernizing and digitalizing the manufacturing supply chain. By reducing the time required for mold production from ten weeks to just two, the VX9000 offers an unprecedented acceleration of the manufacturing timeline. It’s expected to cut hydropower costs by up to 20% and lead times by as much as four months—an extraordinary improvement in efficiency.

During this phase, voxeljet successfully printed 20 benchmark sand molds, each tailored to be transformed into metallic parts used in clean energy applications. This is particularly crucial for turbines like the GE Haliade-X, which recently set a world record by producing 312 megawatt-hours of electricity in just 24 hours. The nacelle of this turbine, made using the VX9000’s molds, is emblematic of the scale and precision required in today’s renewable energy infrastructure.

A collective vision for a clean energy future

The VX9000’s development is a collaborative achievement involving some of the most respected names in industry and academia. GE Hydro, GE Onshore Wind, GE Offshore Wind, Clemson University, Oak Ridge National Laboratory (ORNL), and Hodge Foundry are all key partners in the Advanced Casting Cell initiative. Together, these institutions are building a complete digital foundry ecosystem—one that spans from initial CAD design to the final metallic part.

This ecosystem includes digital workflow optimization, robotic welding technologies, and workforce development programs to equip the next generation of technicians with advanced manufacturing skills. For instance, the development of a robotic welding solution for assembling a >10-ton Francis runner is underway, alongside casting optimizations for a 16-ton rotor hub. These efforts are all geared toward making the United States a leader in cost-effective, domestic production of large-scale energy infrastructure components.

As the VX9000 continues to evolve, its impact is becoming increasingly evident. It’s not just a printer; it’s a cornerstone of the energy sector’s digital transformation. This milestone at Baettr Foundry illustrates how scalable additive manufacturing can fulfill the ambitious goals of a clean energy economy.