"Průmyslovákeramika", a well-known Central European company specializing in ceramic mixtures and custom refractory parts, transformed its traditional production process in 2016 and began using Ultimaker 3D printers to manufacture mold accessories. This led to a fivefold increase in the speed of refractory mold cavity production, a reduction in production costs to 10% of the original, and perfect repeatability.
The original meaning of "Průmyslovákeramika" is "Industrial Ceramics". Founded in 1991, the company currently employs 75 people and produces over 9,500 tons of ceramic mixtures and nearly 1,600 tons of structural parts annually, with an annual turnover of 220 million Czech crowns (9.8 million USD). Their key to success lies in quickly fulfilling customer demands. However, each order for ceramic parts is unique and requires a unique mold design. Therefore, they had to adopt additive manufacturing to meet the large volume of customization requirements, which led them to choose Ultimaker 3D printers.
．Tailored Precision Industry
These molds typically feature a stainless steel shell that shapes the exterior, into which a central mold core is placed to define the internal functionality and details of the part, such as grooves, holes, and curves. These accessories are often complex in shape and must be designed and manufactured according to the precise specifications provided by the client. In the past, these internal modules were made using handmade woodworking or CNC metal inserts; a woodworking accessory could cost up to 20,000 Czech crowns (895 USD) and take over 30 hours to carve, which was both time-consuming and expensive.
(The image shows a ceramic refractory part, finished using a steel mold shell and a 3D-printed mold core.)
In 2013, they began experimenting with 3D printing to accelerate mold production, but their first 3D printer ran into trouble. Jakub Cvilinek, the company's managing director, said: "We tried to overcome various situations with inconsistent print quality; at that time, only about 30% of prints were successful, the rest was waste." Despite this experience, they still believed in 3D printing technology. "This technology was still indispensable for us, even though we had chosen an unsuitable 3D printer at the time."
．Mold Manufacturing Reborn: Ultimaker 3D Printers
It wasn't until 2016 that they found the Ultimaker 3 Extended 3D printer. Finally, the company found a stable and professional 3D printing device. Two years later, Jakub added a new Ultimaker S5 to their arsenal, which, in addition to perfect print quality, featured a simpler user interface and a larger print volume. As the team utilized 3D printing to produce mold cores and other mold accessories, the advantages of the technology emerged: accuracy, speed, and repeatable production—plus greater creative freedom in part design, and most importantly, it was much cheaper than previous processes.
(The image shows Jakub Cvilinek, Managing Director of Průmyslovákeramika, with the production assistant Ultimaker S5.)
For 3D printing mold cores, they only use PLA material because it is easy to use and has a lower melting point and glass transition temperature. Since many core structures are embedded in the ceramic material until they enter the firing process, the specialized PLA material can be completely burned out of the mold when the firing temperature exceeds 900°C, to obtain high-quality hollow mold cavities. Currently, only two operators are responsible for supervising the 3D printers producing the parts, while the components are designed by the engineering department using Autodesk Inventor and AutoCAD, allowing for quick and easy modifications.
(Further reading: The Mystery of 3D Printing to Lost-Wax Casting: PolyCast)
．Industry Transformation is Imperative
"The Ultimaker 3 Extended and S5 have saved us a lot of production time and cost, and moreover, allowed us to produce object shapes that were previously unattainable! With technological advancements, 3D printers will become indispensable production tools," said Jakub. 3D printing has become a crucial asset in the company's manufacturing process, producing required parts about five times faster and ten times cheaper compared to traditional methods. For example, the material for a mold core used in 3D printing an industrial burner's air and gas mixer only costs 300 Czech crowns (13.43 USD). This means that within just a few months, the cost savings will surpass the return on investment from their initial purchase of Ultimaker 3D printers.
(The image shows a 3D-printed blade mold, offering design freedom and easier demolding.)
In addition to reducing reliance on CNC milling, the company also saved production costs from back-and-forth modifications, benefiting from on-site manufacturing, rapid prototyping, and the ability to reproduce parts simply by reprinting the file when necessary.
．3D Printing Allows for More Complex Shapes and Greater Design Freedom
For Průmyslovákeramika, the addition of the Ultimaker 3 and Ultimaker S5 completely transformed their manufacturing process. They are now confident in their ability to meet and even exceed customer quality requirements.
Jakub emphasized, "In the past, some particularly complex mold core shapes were either impossible to manufacture or too costly using traditional methods; but now, we can produce them ourselves using Ultimaker 3D printers."
(Further reading: Metal Parts Here! A Collection of 3D Printing for Casting!)
Does this production process sound similar to your experience? Now, benefit from these advantages with Ultimaker 3D printers and create your company's success story. 3DMart offers excellent print quality and original machines. We believe that print quality determines product value. Feel free to contact us to learn more about industrial-grade 3D printers.
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