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At RAPID 2013, President and COO of ExOne, David Burns, described his company's new ability to print patternless sand casting molds and cores directly from CAD, in a matter of hours. The process is known as Digital Part Materialization, and it represents the transformation of a part from digital space to physical space. The process begins with a digital file of a mold or core. Specialized software slices the design into paper-thin layers. Each layer is transferred to the machine which then physically prints the object layer by layer. Here's how it works: ·A pre-mixed casting media is spread and a binder is selectively dispensed using inkjet printing technology. ·The build platform is then lowered and a new layer of casting media is spread. This is repeated until the mold or core is completed. ·After the part is finished, the unbound sand is removed and the mold or core is extracted and ready for unaltered foundry operations. The Naval Undersea Warfare Center (NUWC) recently used the technology to replace the tail cones of their MK 30 anti-submarine mobile targets. The NUWC provided drawings of the part, which were converted to a CAD file. Using this technology, a foundry had the part designed and the mold package printed in 12 days. For more information on ExOne, visit: http://www.exone.com/