Installation of the VX9000 at the voxeljet site in Friedberg (© voxeljet AG)
Additive manufacturing has primarily been used for prototypes and small series production to date. Conventional systems often reach their limits due to limited build volumes. With the VX9000, voxeljet has teamed up with GE Vernova and Fraunhofer IGCV to develop a system that can produce sand molds for castings weighing up to 60 tons. The aim is to transfer the use of binder jetting technology to large-scale components.
The project was launched in 2021 as part of the development of the Advanced Casting Cell (ACC). This was designed to produce sand molds for the Haliade-X offshore wind turbine much faster and more flexibly than conventional processes. Instead of ten weeks, the production of a mold takes only about two weeks. In addition, decentralized production eliminates a large part of the transport costs, which reduces costs and CO₂ emissions. The German Federal Ministry of Economics funded the project, followed by further support from the U.S. Department of Energy in 2023.
The VX9000 is based on voxeljet’s binder jetting technology. With a build volume of 9 x 7 x 1.8 meters, it is one of the largest 3D sand printing systems in the world. Improved print heads, layer thicknesses of up to one millimeter, and integrated sensor technology ensure short build times and stable process control. The use of cost-effective, locally available sand also contributes to its economic efficiency.
Validation took place at the Baettr Foundry in Sweden in the summer of 2025. Twenty large-format molds for castings up to 7.5 meters in length were successfully produced. The components achieved tight tolerances, had smooth surfaces, and could be cast without any problems. “Today, the cores are larger, easier to assemble, and meet the highest quality standards,” says Nicolas Ory-Studer, Project Manager at Baettr.
Originally developed for offshore wind power, the VX9000 also opens up potential in other areas, such as hydro turbines and heavy gearboxes. voxeljet is thus positioning itself as a partner for large-format additive manufacturing solutions in the foundry sector. The project shows that 3D printing has also reached industrial maturity in the multi-ton range.
