3D Printer HardwareCeramic Additive ManufacturingProduct Launch

New ExOne S-Max Flex sand binder jetting system to debut at CastExpo

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The most affordable sand 3D printer ever offered by binder jetting pioneer ExOne, the all-new S-Max Flex, will debut at CastExpo 2022 in Columbus, Ohio, on April 23. The new machine has been designed from the ground up as a robotic 3D printing system that combines industry-leading binder jetting expertise from ExOne and Desktop Metal (and possibly ETEC Viridis as well). It features Single Pass Jetting technology and will enable more foundries than ever to enjoy the benefits of sand 3D printing technology.

Targeted at the growing number of foundries and pattern shops looking to step into the next era of metal casting, the ExOne S-Max Flex is a simple and easy-to-use sand printing system with a quick payback. By pairing an industrial robot (similar to the one used by Viridis, also part of the Desktop Metal group now), with an all-new printhead and recoater design worthy of the trusted S-Max name, ExOne — in partnership with new owner Desktop Metal —  created an Additive Manufacturing 2.0 system designed to democratize sand 3D printing for the foundry industry.

The combination of multiple sand binder jetting technologies into one company is “bound” to bring significant benefits in terms of leveraging best practices and more efficiently targeting the foundry segment. The benefits of sand binder jetting AM in large foundry core, patterns and mold production has been amply demonstrated as reported in 3dpbm Research’s report on the Ceramic AM market. The new system’s debut at CastExpo 2022 will help drive greater awareness.

New ExOne S-Max Flex sand binder jetting system to debut at CastExpo, combining expertise from all Desktop Metal group companies.
The robotic sand binder jetting system developed by Viridis, a company later acquired by EnvisionTEC, now rebranded ETEC and part of the Desktop Metal group.

With a giant build volume of 1900 x 1000 x 1000 mm (39.4 x 74.8 x 39.4 in), and build rate up to 115 l/h, this new turnkey system was developed to help smaller foundry businesses both survive and thrive into the future. The S-Max Flex allows its owners to offer quick turnaround times on high-quality sand molds and cores regardless of complexity – eliminating the need for traditional core production and assembly, and all the labor, scrap, and complication that comes with it. The S-Max Flex is intended to keep foundries competitive by enabling same-day castings of the complex cores becoming increasingly common as manufacturers consolidate and lightweight metal parts for electric cars and a new future. What’s more, this system enables foundries to operate more efficiently, despite labor shortages and supply chain challenges.

The system on display at CastExpo 2022 will also feature an all-new kinematic Single Pass Jetting printhead and recoater assembly designed by Desktop Metal and tested with input from ExOne’s experienced sand 3D printing team It will be combined with a proven industrial robot enabling a flexible layout and ease of access for routine service and maintenance. Desktop Metal’s easy-to-use Fabricate MFG integration will automatically nest parts within the job box for the highest accessibility.

Composites AM 2024

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Davide Sher

Since 2002, Davide has built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, he spent 12 years in the United States, where he completed his studies at SUNY USB. As a journalist covering the tech and videogame industry for over 10 years, he began covering the AM industry in 2013, first as an international journalist and subsequently as a market analyst, focusing on the additive manufacturing industry and relative vertical markets. In 2016 he co-founded London-based VoxelMatters. Today the company publishes the leading news and insights websites VoxelMatters.com and Replicatore.it, as well as VoxelMatters Directory, the largest global directory of companies in the additive manufacturing industry.

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