Binder Jetting Technology The World's Largest 3D Printer for Sand

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Together with GE Vernova and Fraunhofer IGCV, Voxeljet has developed the world's largest 3D printer for sand molds—the VX9000. It enables the efficient, resource-saving, and localized additive manufacturing of key components for wind and hydropower plants.

Additive manufacturing is predominantly used today for prototypes and small series. The build volumes of common systems often limit the range of applications to smaller components. This might create the impression that 3D printing is only suitable for compact applications. However, in the energy sector, such as in wind or hydropower plants, entirely different scales are required: particularly with wind turbine components like rotor hubs, individual parts can reach weights of up to 66 short tons.

Even in large-scale formats, engineering teams aim for the same goals as with smaller components: maximum design freedom, reduced weight and material usage, shortened lead times, and the possibility of decentralized manufacturing. To transfer these advantages of additive manufacturing to components in the multi-ton range, Voxeljet, together with GE Vernova and the Fraunhofer Institute for Foundry, Composite, and Processing Technology IGCV, has developed the VX9000 3D printing system. For the first time, the system scales industrial binder jetting technology to a level that meets the requirements for multi-ton cast components.

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In September 2021, GE Vernova (then GE Renewable Energy), Fraunhofer IGCV, and Voxeljet launched the joint research project. The goal was to optimize the mold production for cast components of the Haliade-X offshore wind turbine. Using the so-called Advanced Casting Cell (ACC), sand molds for individual parts weighing up to 66 short tons were to be produced faster, more flexibly, and more resource-efficiently than with conventional molding processes.

A key advantage of the planned technology was the drastic reduction in production time: instead of around ten weeks, manufacturing was expected to take just two weeks. Additionally, the use of additive manufacturing at the installation site promised a significant reduction in logistics efforts and the associated CO₂ emissions. The Federal Ministry for Economic Affairs and Energy supported the project as part of a technology-oriented innovation program.

Technology Platform: Binder Jetting on An Industrial Scale

As part of the ACC, the VX9000 3D printer from Voxeljet was designed. It is based on binder jetting technology, in which sand is selectively solidified layer by layer using a binder. This allows the production of complex geometries with high dimensional accuracy. With a build volume of 30 × 23 × 6 feet, the 3D printer surpasses the build volume of all other common 3D sand printers and is thus one of the largest systems of its kind worldwide.

In October 2023, the overall project by GE Vernova was funded with $14.9 million by the U.S. Department of Energy (DoE). Voxeljet was selected as the technical implementation partner to further develop the VX9000.

Prototyping And System Integration

The first VX9000 platform was assembled at Voxeljet's headquarters in Friedberg (Germany). The dimensions of the system significantly surpass existing facilities—the comparison with the VX4000, previously one of the largest commercial 3D printing systems for sand molds, highlights the scaling leap: The VX4000 has a contiguous build volume of 13 × 7 × 3 feet.

In addition to the increased build volume, the VX9000 also stands out with further technological advancements:

• Processing of industrial foundry sands—use of cost-effective, locally available sands with high recyclability; significantly simpler preparation compared to traditional quartz sand.
• Increased layer thicknesses and improved printing technology: Layer thicknesses of up to 0.04 inches accelerate the build process and reduce process costs.
• Offset jetting strategy—Large-format print head setup with very short offset distances for significantly reduced build times.
• Integrated process sensors—Real-time monitoring of relevant process parameters ensures consistent print quality and traceability.

Validation Under Production Conditions

A milestone was reached in the summer of 2025: The first large-format sand molds from the VX9000 were successfully cast at the Swedish Baettr Foundry. In total, 20 benchmark molds were processed in print jobs up to 25 feet long under real foundry conditions. The alloy EN-DJS-400-18-LT was cast, and the final cast part weighs 16,000 pounds.

The following results were achieved:

• Dimensional tolerances were well within the required values
• Significantly higher fitting accuracy of components compared to traditionally manufactured large molds
• Significantly easier assembly of the casting mold
• Reduced cleaning effort for components due to improved surface quality and fewer burrs
• Smooth casting process under series production conditions
• No detectable casting defects
• Initial findings on process optimization in handling and workflow

The validation confirmed the industrial applicability of the system. The VX9000 met both the geometric and casting requirements for critical large components. "Baettr has been working with Voxeljet on the further development of sand 3D printing since 2018. The progress is clearly noticeable: today, the cores are larger, easier to assemble, and continue to meet the highest accuracy and quality standards. With these positive experiences, we aim to actively shape the future of this technology," explains Nicolas Ory-Studer, Project Manager at Baettr.

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Application Spectrum And Scalability

The VX9000 was primarily developed for the offshore wind industry but can be applied to numerous other fields. These include hydroturbines (e.g., Francis runners, spiral casings), heavy-duty rotor hubs and gearbox housings, as well as structural components for large-scale energy or infrastructure projects.

The VX9000 demonstrates how large-scale additive manufacturing becomes an industrial reality. With its modular design, precise binder jetting technology, and digital process integration, it is more than just a technological prototype—it is a manufacturing game changer in the field of large castings.

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