British GW develops 3D printed castings for 300 horsepower outboard diesel engines

China3D printingNet August 2nd, Cox Powertrain, a propulsion system manufacturer headquartered in West Sussex, UK, has selected Grainger & Worrall (GW) headquartered in Shropshire to use a 300-horsepower diesel outboard engine3D printingTechnological development of main engine castings. CXO300 is a 4.4-liter twin-turbocharged V8 engine that can provide higher fuel efficiency for merchant ships, leisure and sea rescue. Due to strong product demand, GW will use the new technology to produce 70 sets of engines per week.

“Achieving world number one requires the support of the best suppliers, and all Cox suppliers must carefully evaluate their capabilities,” said Duncan Green, purchasing director of Cox Powetrain. For Cox, it is very important to cooperate with suppliers because they can provide us with high-quality, precise engine castings in the time scale and required volume.
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Grainger & Worrall and3D printing

With 75 years of experience in automotive and marine casting, GW is committed to digital manufacturing to accelerate the time to market for new products. Recently, the company invested in a third large CT scanner to ensure the quality control of all its components. So far, GW has invested more than 1.2 million pounds in CT technology.

According to GW business development manager Matthias Schoeffmann, the company’s sand castings are made in3D printingManufactured under the support of. Earlier this year, GW used ExOne’s S-max 3D printingThe machine produces large-scale structural aluminum sand castings, and produces water jet propulsion systems for HamiltonJet.

According to China3D printingWang understands that GW also uses COSCAST, in which aluminum alloy is melted and stored in an electric furnace, and then the liquid metal is transported into the sand mold with an electromagnetic pump. COSCAST and GW’s digital process simulation, sand printing, rapid product verification and precision machining work together.

For the CXO300 model, these methods will be affected. GW Director Matthew Grainger said, “The cylinder head and upper and lower crankcases will be produced by Grainger & Worrall as the first series production contract for four important engine castings.
“The innovative casting technology used by our company makes us an ideal supplier for large COX projects, which require the first engine casting delivery to be completed by the end of the year. Our agile and flexible approach is perfect for manufacturers and suppliers The solution is dedicated to shortening the product time and does not require quality control for quality control.”



Sand from Grainger & WorrallCast. The photo is from GW.

3D printingSand casting

3D printingSand castings are regarded as an economical alternative to the production of casting molds, without the need for complex and expensive tools. Like GW, ExOne’s S-Max and the newly launched S-Max Pro also provide support for companies in various applications.
In May, the industrial pump manufacturer and foundry PumpWorks Castings, LLC launched the S-Max system, reducing the lead time for the production of two custom parts from 17 weeks to 8 weeks.

Prior to this, ExOne and the Ohio-based3D printingTooling and parts manufacturer Catalysis Additive Tooling collaborated to create a new3D printingProcessing technology. The first is a sand mold produced on S-Max, and then it is processed using Catalysis’s proprietary coating. This creates a reusable tool that can be used to make plastic, fiberglass, foam or other composite parts in traditional injection, vacuum forming or casting processes.

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