Additive manufacturing is currently used primarily for prototypes and small series. The construction volumes of common systems often limit the area of application to smaller components—a circumstance that can reinforce the impression that 3D printing is only suitable for compact applications. However, in the energy sector in particular, for example in wind or hydroelectric power plants, completely different standards are required: for wind turbines, for example, individual components such as rotor hubs can weigh up to 60 tons.
Project Launch: Development of the Advanced Casting Cell (ACC)
Even in large formats, engineering teams have the same objectives as with smaller components: maximum design freedom, reduction in weight and material usage, shorter lead times, and the possibility of decentralized production. In order to transfer these advantages of additive manufacturing to components in the multi-ton range, voxeljet has developed the VX9000 3D printing system in collaboration with GE Vernova and Fraunhofer IGCV. The system marks a significant technological leap forward – it scales industrial binder jetting technology to a level that meets the requirements for multi-ton castings for the first time.
In September 2021, GE Vernova (formerly GE Renewable Energy), Fraunhofer IGCV, and voxeljet announced the launch of a joint research project to develop a large-format 3D sand printer. The aim was to optimize mold production for casting components for the Haliade-X offshore wind turbine. The Advanced Casting Cell (ACC) was designed to be capable of producing sand molds for individual parts weighing up to 60 tons – faster, more flexibly, and with greater resource efficiency than conventional molding processes.
A key advantage of the planned technology was the drastic reduction in production time: instead of around ten weeks, manufacturing could be completed in just two weeks. In addition, the use of additive manufacturing at the installation site promised a significant reduction in logistics costs 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
The VX9000 3D printer from voxeljet was designed as part of the ACC. It is based on voxeljet's established binder jetting technology. This involves selectively solidifying sand layer by layer with a binder. This allows complex geometries to be produced with high dimensional accuracy. With a build volume of 9 x 7 x 1.8 meters, the 3D printer exceeds the build volume of all other common 3D sand printers, making it one of the largest systems of its kind worldwide.
In October 2023, the entire project was awarded $14.9 million in funding from the U.S. Department of Energy (DoE) to GE Vernova. voxeljet was selected as the technical implementation partner to further develop the VX9000.
The first VX9000 platform was subsequently assembled at voxeljet's headquarters in Friedberg, Germany. The dimensions of the system significantly exceed those of existing systems – a comparison with the VX4000, previously one of the largest commercial 3D printing systems for sand molds, illustrates the leap in scale.
In addition to its increased construction volume, the VX9000 also scores points with further technological advances:
- Processing of industrial foundry sand – use of cost-effective, locally available sand with high recyclability; significantly easier processing compared to traditional quartz sand.
- Higher layer thicknesses and improved printing technology – layer thicknesses of up to 1 mm accelerate the printing process and reduce process costs.
- Offset jetting strategy – large-format print head design with very short offset paths for significantly reduced construction times.
- Integrated process sensors – real-time monitoring of relevant process parameters ensures consistent print quality and traceability.
Validation under Production Conditions
A significant milestone was reached in the summer of 2025: the first large-format sand molds of the VX9000 were successfully cast at the Baettr Foundry in Sweden. A total of 20 benchmark molds were processed in print jobs up to 7.5 m in length under real foundry conditions. The alloy EN-DJS-400-18-LT was cast, and the final casting weighs 7200 kg.
Results:
- Dimensional tolerances were well within the required values.
- Significantly higher accuracy of fit of the components than traditionally manufactured large molds.
- Significantly easier assembly of the casting mold.
- Less cleaning required for the components due to improved surface finish and fewer flashes.
- 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 since 2018 to further develop sand 3D printing. The progress is clearly noticeable: today, the cores are larger, easier to assemble, and continue to meet the highest standards of accuracy and quality. With these positive experiences, we want to continue to actively shape the technology in the future,” explains Nicolas Ory-Studer, Project Manager at Baettr.
Range of Applications and Scalability
The VX9000 was primarily developed for the offshore wind industry, but can be adapted to numerous other fields of application. These include:
- Hydroturbines (e.g. Francis impellers, spiral casings).
- Heavy-duty rotor hubs and gearboxes.
- Structural components for large-scale plants in the energy or infrastructure sector.
Voxeljet as an Engineering Partner for Large-Scale AM Solutions
With the development of the VX9000, voxeljet confirms its role as a technology leader in the field of large-format additive manufacturing for the foundry sector. The combination of many years of experience, engineering expertise, and flexible machine architecture makes the company a reliable partner for industrial projects with high demands on customization, dimensional accuracy, speed, and sustainability.
The VX9000 demonstrates how large-format additive manufacturing is becoming 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 game changer in large-scale casting manufacturing.
