3D-Print. Cast. Sinter.
Introducing 3D-printed shell casting (3DPSC) from voxelcast
— a full-stack additive manufacturing innovation born from cross-disciplinary integration.
One framework that leverages from established production techniques to unlock AM across wide range of sinterable materials.
Why it works
We do not print, melt or bind the metal/ceramics materials layer by layer, and then remove the imparted stress or binder from the volume.
voxelcast deconstruct the geometric definition, material coordination and final thermal densification within additive manufacturing of metal and ceramics.
By doing so, we can assign each function to the process best suited to perform it.
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high resolution resin 3D printing provides the geometric precision,
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suspension processing enables efficient material placement and particle packing,
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furnace sintering produces the final microstructure.
These functions are integrated as a unified workflow, with the engineered 3D printed shell serving as process control interface between the steps.
01
3D shell data generation & workflow management
The voxelcast software converts the original STL file into an optimized shell geometry and automatically defines process parameters for stable slurry casting, controlled consolidation, and homogeneous part formation.
The software environment connects the voxelcast hardware modules into a cloud-based workflow, enabling coordinated production, parameter management, and process traceability.
02
Shell 3D printing
The high-precision, monolithic shell geometry is then 3D printed using photopolymer resin specially formulated for the voxelcast process. Shell cleaning and UV light curing are done as per standard in resin 3D printing protocols.
03
Slurry Casting
Our proprietary slurry is a water-based, highly loaded suspension of metal or ceramic powder. Using the voxelcast automated cast station, the slurry is dispensed into the 3D printed shell and seamlessly fills even fine internal cavities.
In this step, the 3D printed resin shell is not merely a geometric mold; it is also a process-control interface whose physical properties can be tailored to govern how the slurry flows, consolidates, and remains supported.
04
Form consolidation & drying
After filling, the shells are placed inside the voxelcast drying station. A gentle drying phase then removes moisture from under low-heat condition. By the end of this step, a high-strength greenbody is formed inside the shell, ready for the subsequent thermal processing step.
05
Shell decomposition & sintering
voxelcast process is a sinter-based AM route, but without the lengthy high-temperature or chemical debinding step typically required for binder-heavy greenbody.
Using one sinter oven, the photopolymer shell surrounding the exterior of the consolidated greenbody is decomposed during the sintering phase. This one-step thermal processing reduces the debinding-related defects, simplifies the workflow, lowering overall production energy demand and inert gas consumption.