Additive Manufacturing at Warner Brothers Foundry Company
For more than a century, Warner Brothers Foundry Company has been delivering precision non-ferrous castings that meet the toughest performance standards. Today, we continue that legacy of craftsmanship and reliability by integrating additive manufacturing, also known as 3D additive manufacturing, into our casting process. This advanced capability allows us to create intricate, high-quality aluminum, brass and bronze castings faster and more efficiently than ever before.
A Smarter Way to Cast Metal
Additive manufacturing transforms how castings are designed and produced. Instead of relying solely on traditional tooling, we can now 3D print casting patterns, molds and cores directly from digital designs.
At Warner Brothers Foundry Company, we use metal additive manufacturing to complement our existing air-set sand casting methods. This hybrid approach combines the speed and flexibility of digital production with the strength and durability of our proven casting processes. The result is consistent, high-quality non-ferrous castings that meet or exceed ASTM standards such as B26/B26M for aluminum-alloy sand castings and B30 for copper-base alloys.
How Additive Manufacturing Enhances the Casting Process
Additive manufacturing helps our casting process with:
- Tool-less pattern creation: Instead of machining with traditional metal tools, we 3D print master patterns directly from CAD models. This method saves time and cost, particularly for prototypes and low-volume runs.
- Complex mold production: Additive manufacturing allows us to build detailed sand molds layer by layer. This process enables the creation of intricate internal channels and geometries that traditional methods can’t match.
- Direct casting of parts: Emerging additive processes make it possible to form temporary sand mold that can be removed after casting. This technique is ideal for complex or performance-critical components where precision is essential.
The Advantages of Additive Manufacturing
With 3D additive manufacturing technology, you enjoy:
Reduced Lead Times
By creating molds and patterns quickly and accurately, we shorten project timelines and help customers bring products to market faster.
Design Freedom
Our additive manufacturing company can handle custom geometries and complex part configurations without the limitations of conventional tooling, meaning new design possibilities and performance improvements.
Savings
Because additive manufacturing eliminates costly pattern tooling, customers save both time and money while maintaining the same high quality Warner Brothers is known for.
Improved Performance
The precision and repeatability of 3D additive manufacturing enable lighter, stronger and more efficient cast parts. This helps reduce machining time and material waste.
Quality You Can Trust
Every casting we produce, whether conventionally or through additive manufacturing, undergoes rigorous inspection to ensure it meets our internal and customer quality standards.
While additive manufacturing continues to evolve, its impact on the casting industry is already clear. It reduces waste, speeds up production, and enables innovation across industries ranging from defense and aerospace to energy and heavy equipment. At Warner Brothers Foundry Company, we see additive manufacturing not as a replacement for traditional craftsmanship but as a powerful tool that extends what’s possible in non-ferrous casting.
Experience the advantages of additive manufacturing with Warner Brothers Foundry Company. Contact us today to discuss your project, request a quote, or learn how our 3D printing and casting expertise can help you achieve better results faster.
