Pattern Forge High Speed Automatic Pattern Making Machine
"Faster, Affordable & Most Convenient Way To Create Patterns"
Overview
PATTERN FORGE is a state-of-the-art, high speed automatic pattern making machine designed to transform the sand casting industry and tooling solutions for Composite Industry. This innovative machine combines advanced materials and cutting-edge technology to deliver better quality and cost savings in the pattern making process. Developed and manufactured by Deltasys E-Forming Company, Pattern Forge sets a new standard in pattern making, offering superior performance and reliability.
What is Pattern Forge?
Pattern Forge is a cutting-edge, high speed automatic pattern making machine designed to help Sand Casting Industry to make patterns in a faster way. Pattern Forge streamlines the pattern making process, delivering unparalleled efficiency, precision, and cost savings. It is used to produce near net shape patterns and significantly reduce the time, labor and materials typically required for traditional pattern making process.
Engineered for versatility, it seamlessly handles intricate patterns for a wide range of industries, including automotive, aerospace, and tooling. Powered by advanced automation technology, the pattern forge ensures consistent output, drastically reducing production time while maintaining exceptional accuracy.
How Pattern Forge Works?
Pattern Forge employs a two-step process to create high-quality patterns, combining the use of proprietary DE Thermo Fiber resin material and precision CNC milling. Pattern Forge is a system designed to create, customize, and manage intricate patterns for various applications such as CNC machining, 3D printing, textiles, or digital design.
3D Print Near-Net Shape
The process begins by creating a near-net shape using 3D printing technology. In this step, the base structure or rough outline of the final object is produced, closely approximating the desired geometry. The 3D printer uses the digital pattern generated by Pattern Forge to deposit material layer by layer, often employing methods such as FDM, SLA, or SLS. This step is designed to minimize material waste while providing enough excess material in critical areas for subsequent machining. The near-net shape approach balances speed and cost efficiency, as 3D printing can quickly generate a foundational structure without requiring precise details.
CNC Machining
Once the near-net shape is complete, the object undergoes CNC machining to achieve detailed and precise features. The CNC machine removes excess material from the printed structure, focusing on areas that require tight tolerances or fine finishes. The Pattern Forge generated design ensures compatibility with CNC programming, translating into efficient toolpaths for milling, drilling, or turning. This step bridges the gap between the raw 3D printed form and the intricate details needed for the final product, ensuring dimensional accuracy and surface quality.
Achieving the Final Shape
In the final step, finishing touches are applied to achieve the desired shape, surface texture, and functionality. This may involve additional CNC operations, polishing, coating, or post-processing treatments like heat treatment or painting. The combination of near-net shaping and precision machining ensures that the final product meets all aesthetic, functional, and structural requirements. By blending 3D printing and CNC machining, the Pattern Forge workflow optimizes the manufacturing process, reduces waste, and enhances production efficiency, delivering a high-quality end product tailored to exact specifications.
THE PROCESS
Deposition & Final Shaping
Step 1: Material Deposition
Step 2: CNC Milling for Final Shaping
Explore the Core Features of Pattern Forge
Efficiency & Speed
Pattern Forge significantly reduces the time required to create patterns. The automated deposition and finishing processes streamline production, allowing for faster turn around times.
Cost Savings
By minimizing material wastage and reducing the need for manual labour, Pattern Forge helps foundries achieve substantial cost savings. The efficient use of DE Thermo Fiber resin further contributes to cost-savings.
Superior Quality
The combination of proprietary resin material and precision CNC milling ensures high-quality patterns with consistent accuracy. This results in optimal casting outcomes and reduces the need for rework.
User Friendly Operation
Pattern Forge is designed with user convenience in mind. Its intuitive interface and straightforward programming make it accessible to operators with varying levels of technical expertise.
Versatility
Whether you need simple or complex patterns, Pattern Forge deliver. Its ability to handle different sizes and designs make it an invaluable asset for foundries with diverse pattern making needs.
Reliability & Support
Backed by Deltasys E-Forming Company's commitment to quality and customer support, Pattern Forge offers reliable performance and ongoing assistance to ensure your operations run smoothly.
Materials & Applications
Technical Specifications
Pattern Forge High Speed Automatic Pattern Making Machine | |
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Configuration
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Dual Gantry type, Dual Table, Dual Head and Dual Control System
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Table size (X, Y) (Both have separate table) |
For Deposition Head (3D Printing): 1100mm x 1100mm x 1100mm For CNC Machining: 1100mm x 1100mm x 1100mm |
Head Travel
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For Deposition Head (3D Printing): 1100mm x 1100mm For CNC Machining: 1100mm x 1100mm x 1100mm |
Max Print Height (Z) (Both 3D Printing & CNC Machining)
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600mm
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Operation
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Simultaneous operation of deposition and CNC Machining
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Available Print Heads
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DE Linear Melt Pump Head comes with 1.8Kw Servomotor and 20:1 Gearbox
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Max Print Rate (Polymer and Part Geometry dependent)
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11.5Kg/Hour
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Maximum Deposition Temperature
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300°C
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Material Type
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DE Thermo Fiber resin (Granular Form)
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Automatic resin loading to head by vaccum
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Yes
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Deposition Bed Platform
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Made up of Aerospace Grade Aluminium 16mm thick CNC Machined platform heated up to 120°C
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Control System
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DE 3 Axis Deposition Controller comes with Leadshine Servo drives and motors of 750Watt
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Gearbox for X, Y Motion
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10:1 Planetary Gearbox
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High Precision Rack and Pinion (Grounded) for X, Y Motion
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Grounder Rack and Pinion which gives the 50 Micron accuracy
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Ball screw for Z motion
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Both for Deposition Head and CNC Head
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Guideways for X, Y, Z
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Both Deposition Head and CNC Head
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Drag Chains for Cable movement protection
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Yes
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Lubrication for both gantries
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Pump system is given for both the gantries
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Bellows
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Yes
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Enclosure
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Entire Machine comes with Enclosure with Enclosure casing and door system from both the sides, Door system is Airtight
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Pattern Forge High Speed Automatic Pattern Making Machine | |
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Number of Axis
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2 Axis (VMV Type)
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Spindle Power
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6Kw
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Spindle Power
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ER 32 Manual Tool Changing, Air Cooled (ATC BT30 Head is Optional)
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Spindle RPM
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18,000-24,000rpm
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Spindle Make
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HiTECO Italy
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CNC Controller
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Fanuc Oi-MF Plus
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Servo Motors & Drivers
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Fanuc
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Motor Capacity
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1Kw each For X-axis 1Nos, Y-axis 2Nos and Z-axis 1Nos Total 4 motors |
Repeatability
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0.05mm
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Positional Accuracy
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0.2mm/Meter
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Max Cutting Feed
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15000mm/Min
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Rapid Traverse
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20000mm/Min
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Pattern Forge High Speed Automatic Pattern Making Machine
Extra Ancillary and Accessories Customer Should Bye |
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Servo Stabilizer: 10kva
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Hot Air Dryer to remove the moisture from raw material 50Kg Capacity
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Liquid Chiller to cool the feeding zone of Deposition Head
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Fume Extractor to remove the fumes from chamber
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Dust Collector
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Related Resources
From Art to Automation: The Evolution of Pattern-Making in Foundries
The Future of Foundries: Automation, Speed, and Precision in Pattern-Making
Pattern Forge FAQ
Thankyou for visiting our website Do you have questions about our company or various products? We will be happy to help you
General Questions
Pattern Forge is a high-speed, automatic pattern-making machine designed for the sand casting industry. It uses advanced digital and additive manufacturing technologies to create precise, durable, and cost-effective patterns faster than traditional methods.
Pattern Forge automates the pattern-making process, reducing dependence on skilled labor. Unlike traditional methods using wood or aluminum, it offers faster production, reduced material wastage, and greater accuracy.
Pattern Forge uses specially designed materials optimized for sand casting patterns, ensuring durability, strength, and reusability.
For Foundry Owners
Pattern Forge eliminates outsourcing expenses, reduces wastage, and significantly shortens lead times for pattern production. Its efficiency minimizes downtime and optimizes production schedules.
Most foundries achieve ROI within a few years due to cost savings on pattern outsourcing, reduced material costs, and faster production cycles. The exact time depends on the volume of patterns produced.
By offering faster turnaround times and high-quality patterns, foundries can meet tight deadlines, attract more customers, and secure contracts that demand precision and speed.
For Foundry Managers & Plant Heads
Yes, Pattern Forge is designed to integrate seamlessly into most foundries. It complements existing processes and works alongside other equipment like molding machines and CNCs.
The machine is user-friendly and comes with an intuitive interface. Basic training provided during installation ensures your team can operate it efficiently.
Pattern Forge is built for scalability, capable of producing multiple patterns consistently and accurately for small to large-scale production requirements.
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For Operation Managers
With its automated operations, Pattern Forge drastically reduces the time needed for pattern production, ensuring faster mold-making and casting.
Routine maintenance includes cleaning, inspection of components, and occasional software updates. Deltasys E-Forming offers comprehensive service support to keep your machine running optimally.
Pattern Forge supports complex and intricate designs with ease, thanks to its advanced additive manufacturing and design capabilities.
For Pattern Shop Personnel and Supervisors
No, Pattern Forge complements your workforce by automating repetitive tasks, freeing skilled workers to focus on higher-value activities like quality control and innovation.
The machine uses precise digital technology, ensuring accurate dimensions, smooth surfaces, and high durability with minimal manual intervention.
Pattern Forge is compatible with popular CAD/CAM software, making it easy to import and produce designs directly from digital files.
Technical and Installation Questions
Pattern Forge requires a standard industrial workspace with adequate ventilation and power supply. Specific dimensions and requirements will be provided during the consultation.
Installation typically takes a few days, including training. Most foundries can start production within a week of installation.
Yes, the machine includes IoT capabilities, enabling remote monitoring, diagnostics, and software updates for uninterrupted performance.
Security Concerns
All customer data and designs are handled with strict confidentiality protocols. If needed, we offer secure, offline operation modes to protect sensitive information.
Yes, Pattern Forge includes user authentication and access control features to ensure only authorized personnel can operate it or access stored designs.
Financial and Leasing Questions
We offer flexible financing options, including leasing and installment plans, to reduce upfront costs and make Pattern Forge accessible to all foundries.
Leasing allows you to use the machine for a fixed monthly or yearly fee. This reduces capital expenditure and provides flexibility to scale operations.
Future Prospects
Pattern Forge is designed to be future-proof, with software upgradability and compatibility with emerging Industry 4.0 technologies.
We provide end-to-end support, including training, maintenance, and upgrades. Our dedicated customer service ensures your machine operates at peak efficiency.
Pattern Forge minimizes material waste, reduces energy consumption, and supports sustainable manufacturing practices, helping foundries meet their environmental objectives.
FAQs: Pattern Forge vs. Conventional 3D Printing
General Comparison
Pattern Forge is specially designed for the sand casting industry, optimized for creating patterns used in mold-making. Conventional 3D printers are general-purpose devices used for a wide range of applications, such as prototyping, small-scale manufacturing, and artistic designs.
Pattern Forge focuses on speed, durability, and compatibility with foundry workflows, producing robust patterns ready for industrial casting. Conventional 3D printers may lack the necessary material strength and scalability for foundry applications.
Material and Design Differences
Pattern Forge uses specialized materials tailored for sand casting patterns, ensuring they withstand high temperatures and pressures. Conventional 3D printers often use plastics or resins, which may not be durable enough for foundry use.
Yes, Pattern Forge is optimized for intricate and complex geometrics specific to casting patterns. While conventional 3D printers can handle detailed designs, they might require post-processing or additional support structures.
Performance & Speed
Yes, Pattern Forge is designed for high-speed production, delivering patterns much faster than traditional 3D printers, which often have slower build times for larger parts.
Pattern Forge excels at producing patterns for multiple use cases in industrial quantities, whereas conventional 3D printers are more suited for low-volume production or one-off prototypes.
Usability & Integration
Pattern Forge is tailored for foundry applications with intuitive controls and minimal setup time. Conventional 3D printers often require more specialized knowledge for material handling and setup.
Yes, Pattern Forge is built with foundries in mind, ensuring seamless integration into mold-making processes. Conventional 3D printers may require additional steps to adapt their outputs for foundry use.
Cost & ROI
While the upfront cost of Pattern Forge may be higher, its specialized functionality, faster production, and durability result in better ROI for foundry operations. Conventional 3D printers may appear cheaper but often incur hidden costs due to slower production and unsuitable materials.
For Foundries, Pattern Forge offers a significant better ROI by reducing lead times, improving pattern durability, and cutting overall production costs compared to general-purpose 3D printers.
Durability and Maintenance
Yes, Pattern Forge produces patterns that are specifically engineered for the rigors of sand casting, while patterns from conventional 3D printers may lack the necessary strength and thermal resistance.
Pattern Forge is designed for industrial reliability with lower maintenance requirements compared to conventional 3D printers, which often need frequent calibration and material-specific adjustments.
Industry-Specific Benefits
Not entirely. While some 3D printers can produce patterns, they often fall short in terms of speed, material compatibility, and durability needed for foundry applications.
Yes, Pattern Forge minimizes material waste and energy usage, focusing on efficient production tailored to the foundry industry. Conventional 3D printing often generates more waste due to support structures and limited material reuse.
Future Prospects
Pattern Forge is not a replacement for general-purpose 3D printers but a specialized solution for foundries. It can coexist with conventional 3D printers to address specific casting needs.
Pattern Forge includes advanced digital features like IoT-enabled monitoring and compatibility with CAD/CAM software, aligning foundries with Industry 4.0 standards more effectively than conventional 3D printers.
DELTASYS E-FORMING invents, designs and builds specific high tech and high production 3D Printing Machines & CNC Machining Centres.
- +91 8050583644
- info@3deltasys.com
- ARS No. 703/1, Plot No.30, behind GIT College, beside Omkar Roadways, Udyambag Industrial Area, Udyambag, Belagavi, Karnataka 590008-INDIA
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