Our Success Story: Rapid Turbocharger components using 3D-Printed Sand Cores

Our Role:

💻 Design Interface + DFM Input

Worked closely with the customer’s R&D team during early design. Exchanged 3D models directly, providing castability feedback on draft angles, feeding paths, and core removal strategies.

These inputs helped avoid late-stage design reworks and accelerated validation.

🖨️ 3D Printed Core Production

In order to accommodate varying volute sizes across different product variants, complex cores were 3D-printed directly from CAD through “Concurrent engineering” practices, eliminating the need for separate core boxes, shell cores or related tooling investments.

This reduced upfront cost and enabled faster iterations.

🏭 Casting & Process Control 

Using our simulation softwares such as Magma Soft and Nova Flow, we ensured directional solidification and minimized shrinkage defects. Controlled melt chemistry and pouring practices were aligned with Tier-1 production specifications. NOVA_FILLING.avi

Both Iron and Aluminum housings were poured on our dedicated Furan-based binder lines with imported sand to ensure repeatability.

🔧 Machining

These housings were finished on multi-axis CNCs, with flange flatness and volute profiles held to tight tolerances.

Because volute geometries are especially sensitive in R&D, affecting both thermal durability and efficiency, design changes were frequent. By using a fixtureless, modular machining set-up, we could adapt quickly to each iteration, ensuring test-ready parts without tooling delays.

This gave the customer “Speed to market” while still exploring thermal and flow-critical design changes.

🚚 Rapid Deliveries

The first prototypes were shipped in less than ~ 4 weeks.

Each batch included complete CMM reports and inspection data, providing the customer with full confidence in validation readiness.

The Advantage:

Magna’s flexible, tool-free casting workflows have allowed our customers to validate Turbo components under real-world load cycles months ahead of schedule.

Since then, we have continued to support Tier-1s with rapid deliveries in both Compressor (Al) and Turbine (Fe) housings.

And, today, we are ready to deliver the next wave of Turbocharger components!