Over 2 Billion CNY Invested: KOCEL Group Completes “3D+” Transformation in High-End Component Casting

With nearly six decades of foundry expertise, KOCEL Group—an industry leader—has embraced the transformative tides of high-end, intelligent, and eco-conscious manufacturing. By integrating cutting-edge innovations such as 3D printing and robotics into its green smart factories, the Group has spent over a decade in relentless innovation, culminating in the full-scale “3D+” transformation of its high-end equipment casting operations in 2025.

I. Breaking Free from Traditional Resin Sand Casting: A Transformation Imperative

Conventional resin sand casting has long been plagued by four major limitations:

1. Rigid traditional processes hinder product structural innovation and performance optimization.

2. Mold production is costly and time-consuming, stifling R\&D agility and market competitiveness.

3. Production remains complex and quality control difficult due to dependencies on molds, processes, and skilled labor.

4. The harsh working environment, significant safety risks, and high labor intensity deter talent.

Transformation is not optional—it is necessary.

II. Pioneering the Path: KOCEL Group’s “3D+” Transformation Journey

Through investments exceeding 2 billion CNY, KOCEL Group assembled expert teams and conquered core challenges in 3D printing materials, processes, software, hardware, and system integration. Seven smart factories were newly built or upgraded, and all affiliated foundry enterprises have achieved comprehensive “3D+” transformation.

A. Technological Breakthroughs: Industrializing 3D Printing in Foundry Applications

Since 2012, the Group has focused on mastering key technologies in casting-grade 3D printing materials, processes, and software/hardware integration. In 2016, it successfully developed China’s first large-format, high-efficiency industrial-grade 3D printer for casting: the Idream 2518 (2500×1800×1000).

Idream 2518 Industrial 3D Printer for Casting

B. Generational Upgrades: Three Waves of Factory Evolution

First Generation (2013, Ziyang, Sichuan):

The world’s first 3D printing-based digital foundry workshop was launched in Ziyang, equipped with 14 large-format 3D printers, heavy-load RGVs, and integrated digital management systems. It pioneered production line-level applications for 3D printed casting.

Second Generation (2017, Yinchuan, Ningxia):

The world’s first 10,000-ton 3D printing smart foundry went live, featuring 14 sand mold 3D printers, AGVs, gantry robots, and intelligent storage. Powered by a remote operations platform, it delivered over 20,000 tons of sand molds annually—a model of large-scale, efficient sand 3D printing.

Third Generation (2021, Wuhu, Anhui):

The Yangtze River Delta’s first full-process 3D printing foundry was completed. Compared to its predecessor, it reduced construction costs by over 20% and operating costs by over 30%. It could supply sand molds in 3 days and deliver castings in 7–15 days. With 3–5× efficiency gains and significant quality improvements, it set a new benchmark in intelligent casting.

C. Scaled Replication (2023, Quanzhou, Fujian):

In 2023, a new full-process smart foundry opened in Quanzhou, equipped with 3D printers, AGVs, gantry robots, automated batching and pouring systems, and a flexible FMS machining system. Integrated with the KOCEL FOM operational platform, the plant achieved seamless sand core cleaning, assembly, pouring, cooling, and post-processing. Key localization and automation metrics reached:

 100% domestic production of major equipment and software

 100% CNC adoption for critical equipment

 100% automatic data acquisition for core processes

Smart manufacturing maturity was certified above Level 3.

D. Revitalizing Legacy Plants: Full “3D+” Upgrades

In 2025, ten AJS 3200 sand 3D printers and seven AJS 4000 super sand printers were deployed in traditional iron and steel foundries. With comprehensive “3D+” enablement and the integration of new technologies, materials, and tooling, the Group completed China’s first “3D+” transformation of both large cast iron and heavy steel casting enterprises.

First “3D+” Large Cast Iron Enterprise

First “3D+” Heavy Steel Casting Enterprise

Today, all KOCEL Group’s foundries have achieved full “3D+” transformation—enabling digital design, manufacturing, and management. Production processes have been streamlined, cycle times shortened, efficiency doubled or tripled, and defect rates reduced by approximately 20%. The once “clunky and dirty” image of foundries is giving way to a new era of sleek sophistication.

Looking Ahead

Guided by its 15th Five-Year Plan, KOCEL Group will continue to champion innovation, green intelligence, and high-efficiency manufacturing. It will further expand the industrial application of “3D+” and explore frontier technologies such as “Digital Twin+” and “AI+” to achieve high-quality, leapfrog growth—setting a new benchmark and infusing new energy into the high-end, intelligent, and sustainable development of the foundry sector.

Event Preview

KOCEL Group Smart Manufacturing Open Day (Phase IV) will be held in Yinchuan, Ningxia this June. Registration is now open—scan the QR code below to join.

 Event Name: KOCEL Group Smart Manufacturing Open Day (Phase IV)

 Event Dates: June 18–20, 2025

 Venue: Yinchuan International Exchange Center Hotel (222 North Qinshui Street, Jinfeng District, Yinchuan)

△ Scan the QR code to register for the event