Foundry Lab Launches Direct 3D Metal Casting Service for Faster Production

By on February 4th, 2025 in news, Service

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Foundry Lab has introduced a new direct 3D print service.

The New Zealand-based company developed a very unique manufacturing process that is a mix of 3D printing and casting. They call it “metal parts by lunchtime”, the “Digital Metal Casting” process.

And it’s actually true. The now seven-year-old company’s process involves these steps:

  • A design is produced for a metal part.
  • The corresponding mold is created, involving two separable halves.
  • The molds are 3D printed using a binder jet process with ceramic powder.
  • The printed molds are “green” parts, and they’re placed into a microwave device.
  • The microwave cures the printed molds, which are brittle, but able to withstand high temperatures.
  • The two molds are designed to bolt together, forming a void inside corresponding to the original part.
  • The bolted mold is placed upright and metal ingots are placed on top where the sprue would appear.
  • This is all placed back in the microwave for a high-temperature treatment.
  • The heat melts the ingots, which then flow by gravity into the void.
  • A vacuum extracts any trapped bubbles.
  • A gas quenches the mold, and it’s room temperature after only 30 minutes.
  • The part is removed from the mold, the sprue is trimmed off, and you have your fully solid metal part after as little as five hours.

You can see that parts can indeed be made by lunchtime if you start early in the day.

The news is that they’ve opened up a direct-to-business casting service based on their technology. They explain:

“Introducing Foundry Lab Direct , our on-demand casting service that delivers high-quality cast parts directly to your door — in weeks, not months.

With Foundry Lab Direct, you can order parts without committing to tooling or enduring foundry delays. Whether you’re prototyping, handling short-run production, or safeguarding against supply chain risks, our service is here to simplify and accelerate your manufacturing process.”

They say it’s ideal for short-run production, metal prototyping, emergency manufacturing, and reduced lead times.

The service no doubt leverages their in-house equipment, and not only provides a service as above, but also can provide an introduction to their technology to businesses.

Many other 3D print companies have used this “try before you buy” approach, and it works quite well. Typically, customers will like the products and order more products. At some point, they realize that it may make sense to have their own system in-house, and a sale is made.

I’m pretty sure that Foundry Lab is hoping this effect occurs, and it probably should: they have pretty amazing technology that produces metal parts quickly in almost any metal.

Via Foundry Lab Direct

By Kerry Stevenson

Kerry Stevenson, aka "General Fabb" has written over 8,000 stories on 3D printing at Fabbaloo since he launched the venture in 2007, with an intention to promote and grow the incredible technology of 3D printing across the world. So far, it seems to be working!