Blog The revolutionary 3D metal printing project for operational conditions is entering its final phase: Innovation paving the way for accelerated production of pres

The 3D metal printing project, uniting three universities with the foundry and engineering holding MOTOR JIKOV GROUP, is nearing completion as it enters its fourth year of implementation. Recent insights from the team meeting held at MOTOR JIKOV Group a.s. headquarters in České Budějovice confirmed expectations of increased durability of the newly used materials for aluminum pressure casting molds.

"We have tested lightweight cores and are working on a variant to lighten the valve, which allows for more efficient mold cooling. The cores were tested in the operational environment of MOTOR JIKOV Foundry a.s., Pressure Casting division, where we achieved 127,000 shots on a single mold, demonstrating the exceptional lifespan of the H13 material. We are now focusing on testing cores made from DIEVAR material with a gyroid structure mimicking organic design. For the valve, we managed to reduce the amount of material used by up to 30 percent, though the material stability was insufficient. Ultimately, we utilized valves with a 15 percent reduction in material. These innovations will also be tested in the operations of MOTOR JIKOV Foundry a.s., Pressure Casting division, throughout 2024," explained docent Ladislav Socha from the Environmental Research Department at the Czech Technical University in České Budějovice.

The project, co-financed by the state’s Technology Agency and with a budget of 53.8 million CZK, focuses on developing modern molds for aluminum alloy pressure casting using additive manufacturing technology. The new molds made from tool steel H-13 and a modified steel DIEVAR aim to enable faster and more efficient responses to customer needs in the automotive industry.

Results from testing additively manufactured molds are being conducted directly within the Pressure Casting division, with final results expected by the end of 2024. The project team comprises three universities: the Technical University of Liberec, the University of West Bohemia in Pilsen, and the Vysoká škola technická a ekonomická (University of Technical and Economic Studies) in České Budějovice. The South Bohemian university focuses on operational experiments, quality assessment, numerical simulations, and 3D measurements.

"Collaboration with universities has proven to be very fruitful. The results of industrial research then enable innovations that significantly improve the quality and stability of the manufacturing process. Material savings during production are a key aspect, not only decreasing costs but ultimately leading to more environmentally friendly manufacturing and reduced greenhouse gas emissions from production," emphasized Miroslav Dvořák, CEO of MOTOR JIKOV Group a.s.