Humans have been using the same method to cast metal parts for millennia: pouring molten metal into molds, typically crafted from compacted sand and clay.
This ancient technique persists today due to its cost-effectiveness and compatibility with both ferrous and nonferrous metals. However, it has a drawback in its wastefulness, requiring more metal than necessary for the finished part and resulting in energy waste during excess metal melting. While 3D printing offers an alternative, it’s often expensive and mainly used for prototypes and low-volume parts.
A startup called Magnus Metals is revolutionizing metal casting with a technology that rivals the speed and energy efficiency of 3D printing while remaining cost-competitive with sand casting.
Magnus Metals employs a method known as digital casting, combining aspects of sand casting and 3D printing. Their software slices designs into layers, creating ceramic forms to hold the metal during cooling. In the casting machine, metal is melted and dripped into the ceramic base, layer by layer, ensuring strong bonds and minimal defects. These parts are reported to be 10% to 20% stronger than traditionally cast parts.
The company plans to sell its machines and proprietary ceramics, aiming for substantial recurring revenue per machine. Unlike 3D printing, their system can use various customer-specified materials and doesn’t require expensive tooling for base creation.
Magnus Metals recently secured a $74 million Series B funding round led by Entrée Capital and Target Global, signaling a significant step toward industrialization and beta testing.
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