Hänssler LFAM technology opens up new possibilities in 3D printing mold

Mold making is as old as industrialization itself. Some of the technologies, materials and processes used are just as old. New processes can revolutionize entire industries, make them more efficient or more sustainable – and thus help to remain competitive. In modern toolmaking, such as GRP mold making and fiberglass mold making, 3D printing mold making is increasingly being used to produce a GRP negative mold or a precisely fitting casting model, for example. With LFAM, not only sand casting models and other individual models can be realized, but also a complex deep-drawing mould. Whether a casting model made of wood, a casting model made of polystyrene or plastic, 3D printing mold making shortens development times and saves material.

What exactly is mold making with different casting pattern types?

Making a mold is the development and production of negative tools (mold making for negative molds), which are used in series production to manufacture components from plastics, metals or composite materials with precise fit and repeatability. In addition to traditional processes such as plaster mold making or concrete mold making, additive processes such as 3D printing mold making are also used today – often in combination with CNC milling or hybrid processes. The result: high precision, excellent surface quality and maximum resource efficiency. Professional mold making shortens development cycles, reduces unit costs and increases quality and sustainability.

What is behind the LFAM process of 3D printing mold making?

LFAM (Large Format Additive Manufacturing) is an additive manufacturing process in which large plastic parts are built up layer by layer from thermoplastic material using fused deposition modeling. Targeted glass or carbon fiber reinforcement creates enormous stability and precision – even for components several meters long. Whether as a casting model for lost models in sand casting, as a GRP negative mold for laminating processes or as a stable deep-drawing tool: LFAM enables fast digital iterations, high material efficiency and minimal post-processing.

How can LFAM change mold making GRP with different casting pattern types or make it more efficient?

Mold making is used in many industries and technologies:

sand casting, chill casting, pressure die-casting

(sand casting pattern, sand casting lost pattern)

deep drawing

(deep drawing mold material, deep drawing mold production)

laminating

(GRP mold making, glass fiber mold making, plaster mold making)

concrete casting

(concrete mold making, concrete casting mold XXL)

plastic injection molding, extrusion, blow molding

prepreg and RMT

stamping

ceramic casting

Most molds today, such as an XXL casting mold, a deep-drawing mold or a sand casting model, are based on metal. In processes such as sand casting or vacuum deep drawing, wooden patterns or PU models are often used, which are elaborately joined and machined. This results in long processing times and waste, which leads to high costs. Different casting pattern types are made of wood, polystyrene, fine-cell PU or other materials and they only achieve a short service life.

This is where LFAM scores:

Long service life thanks to reinforced plastics with glass or carbon fiber

We manufacture durable components that perform reliably even under high loads. This extends maintenance intervals and reduces downtime.

Little waste thanks to near-contour printed blanks

through precise shaping of the blanks, hardly any excess material is produced. This conserves resources and minimizes the need for post-processing.

Use of recycled material

We use recycled plastics for environmentally friendly solutions that deliver strong technical performance.

Fast customization thanks to end-to-end digital processes

From design to production, all steps are seamlessly integrated through digital processes. This allows for rapid and efficient adjustments.

Why is 3D printing mold making with the LFAM process suitable?

Large molds for manual laminating processes have been benefiting from the innovative LFAM process for some time now. Expensive aluminum or wooden tools can also be replaced by a printed deep-drawing mold in vacuum deep-drawing. LFAM is ideal for sand casting models, casting patterns or GRP negative molds in the mold making sector. It even opens up new perspectives in mold making, model making, concrete casting molds and plaster mold making.

Conclusion

Mold making is as old as the industry itself. The new LFAM technology from Hänssler makes it possible to print plastic molds in sizes and designs that were previously unthinkable. Whether sand casting lost pattern, deep-drawing mold, casting mold concrete or plaster mold, different casting pattern types like wood, polystyrene or glass fiber reinforced plastic – LFAM opens up innovative, efficient and sustainable ways in modern mold making.

Fazit

Formenbau ist so alt wie die Industrie. Die neue LFAM-Technologie von Hänssler ermöglicht es, Formen in Größen und Ausführungen aus Kunststoff zu drucken, die vorher undenkbar waren. Ob Sandguss verlorenes Modell, Tiefziehform, Gießform Beton- oder Gipsform, Gussmodell aus Holz, Styropor oder glasfaserverstärktem Kunststoff – mit LFAM eröffnen sich innovative, effiziente und nachhaltige Wege im modernen Formenbau.