CO-NELE Intensive Mixer for Foundry Sand Preparation & 3D Sand Printing

Advanced Sand Mixing Solutions for Foundry and Additive Manufacturing Industries

Industrial 3D sand printing, commonly based on binder jetting technology, transforms digital casting designs into physical sand molds and cores through layer-by-layer material deposition and selective bonding.

CO-NELE intensive mixers provide efficient foundry sand preparation with uniform mixing, optional heating and temperature monitoring for casting and 3D sand printing applications.

CO-NELE Intensive Mixer for Foundry Sand Preparation & 3D Sand Printing

1. Product Overview

The CO-NELE Intensive Mixer is designed for efficient mixing and preparation of foundry sand, providing reliable solutions for conventional sand casting and industrial 3D sand printing applications.

Featuring an inclined intensive mixing structure and a three-dimensional turbulent mixing principle, the mixer generates intensive material movement and interaction inside the mixing chamber. This promotes uniform distribution of sand particles, binders, catalysts and other additives.

Boasting a wide sand mixing capacity range of 0.3t/h to 60t/h, CO-NELE intensive sand mixer flexibly adapts to the production needs of different enterprises and drives the transformation and upgrading of the foundry industry toward intelligence and digitalization with its hardcore technical strength.

With optional heating systems, temperature sensors and automated control, CO-NELE intensive mixers help foundries improve sand preparation consistency, process stability and production efficiency.

CO-NELE also holds a utility model patent for a sand mixing system for 3D printing equipment, demonstrating its capabilities in integrated sand preparation, temperature control and automated material feeding.

2. Key Advantages

01. Intensive Mixing Performance

Intensive material movement promotes effective contact between sand particles and additives, helping achieve homogeneous mixing and consistent material distribution.

02. Uniform Material Distribution

Optimized mixing action helps distribute binders, catalysts and functional additives throughout the sand mixture, supporting stable sand properties and reliable molding performance.

03. Heating & Temperature Monitoring

Optional hot-air heating systems and temperature sensors allow real-time material temperature monitoring and control, helping maintain suitable sand preparation conditions.

04. Automated Process Control

PLC-based control systems support adjustable mixing parameters, accurate material proportioning and repeatable operating procedures, improving production consistency.

05. Flexible Process Configuration

Mixing time, operating speed and equipment configuration can be adjusted according to different sand characteristics and production requirements.

3. 3D Sand Printing Process & CO-NELE's Role

CO-NELE intensive mixers are integrated into the upstream sand preparation stage, providing uniformly mixed and appropriately conditioned sand for the printing equipment.

CO-NELE Intensive Mixer for Foundry Sand Preparation

Typical 3D Foundry Sand Printing Process

Step 1. 3D Model Design

A casting mold or core is designed using CAD software. The 3D model is then sliced into multiple cross-sectional layers to generate printing instructions.

Step 2. Sand Storage & Proportioning

Different sand materials (quartz sand, silica sand, ceramic foundry sand, etc.) are stored separately and accurately weighed according to the required formulation. Fresh sand, reclaimed sand and other applicable materials can be proportioned according to the process requirements.

Step 3. Intensive Sand Mixing & Temperature Conditioning

CO-NELE intensive mixers blend the sand and specified additives to achieve consistent material distribution. Optional heating and temperature monitoring systems help maintain the required sand temperature.

Step 4. Screening & Material Feeding

The prepared sand passes through a screening system to remove agglomerates and unwanted particles before being transferred to the 3D printer.

Step 5. Layer-by-Layer 3D Printing

The printing machine spreads a thin layer of sand across the build platform. Its printhead selectively deposits binder onto designated areas according to the digital model. This process is repeated until the complete mold or core is formed.

Step 6. Curing & Sand Removal

After printing and the required curing period, the finished sand mold or core is removed from the surrounding loose sand. Unbonded sand can be collected and processed for reuse where permitted by the material and production process.

Step 7. Casting Application

The finished sand mold or core is inspected and prepared for subsequent metal casting operations.

Note: Actual process configurations vary according to the 3D printing technology, sand formulation and binder system. Some systems mix catalysts or additives into the sand before printing, while others selectively apply the binder during printing.

4. CO-NELE's Patented Sand Mixing System for 3D Printing Equipment

CO-NELE has developed an integrated sand mixing system specifically designed for 3D printing equipment, addressing critical challenges in sand proportioning, temperature management and material preparation.

Patent Name: Sand Mixing System for 3D Printing Equipment

Key Technologies of the Patented System

- Accurate Sand Proportioning

Multiple sand storage bins, weighing sensors and metering devices enable different sand materials to be proportioned according to preset formulations, improving raw material consistency.

- Integrated Intensive Mixing

The mixing unit combines different sand materials and specified additives to achieve uniform material distribution before printing.

- Hot-Air Heating Technology

An integrated hot-air heating device directly heats the sand inside the mixing chamber, helping the material reach and maintain the required processing temperature.

- Real-Time Temperature Monitoring

Temperature sensors monitor the sand temperature during mixing, allowing the heating system to respond to process requirements.

- Integrated Screening & Feeding

After mixing, the prepared sand is discharged into a vibrating screening system to remove agglomerates before entering the 3D printer.

- Automated Control

The integrated electrical control system coordinates material storage, weighing, mixing, heating and discharging operations, supporting a more automated sand preparation process.

Patent Innovation: More Accurate Sand Temperature Control

Temperature stability is an important factor in industrial 3D sand printing.

Traditional solutions may rely on constant-temperature workshops to reduce fluctuations in material temperature. However, maintaining an entire workshop at a controlled temperature can increase infrastructure and operating costs.

CO-NELE's patented system uses hot-air heating and temperature sensors to directly control the temperature of sand during mixing.

This approach provides a more targeted way to manage material temperature and helps reduce dependence on constant-temperature workshop conditions.

The system is designed to improve the consistency of prepared sand and support the dimensional accuracy, strength and appearance requirements of 3D-printed components.

Six CO-NELE Foundry Sand Mixers

5. Real Project Application: Six CO-NELE Foundry Sand Mixers

CO-NELE's foundry sand mixing technology has been implemented in industrial 3D printing production.

In September 2025, six CO-NELE foundry sand mixing machines were successfully installed and put into operation in an industrial 3D printing project.

The equipment features:

- Inclined intensive mixing structure.

- Hot-air heating system.

- Integrated mixing temperature sensors.

- Adjustable operating parameters.

- PLC-based automated control.

The system integrates sand preparation with the existing 3D printing production process, providing a stable supply of prepared sand for industrial manufacturing.

This project demonstrates CO-NELE's experience in developing integrated sand mixing solutions for advanced foundry applications.

6. Main Application Fields

- 3D Printing Foundry Sand

Preparing and conditioning selected sands for industrial binder jetting processes, according to the printer manufacturer's material specifications.

- Green Sand

Mixing molding sand with bentonite, coal dust and other additives.

- Ceramic & Special Foundry Sand

Preparing specialty sand mixtures for precision casting and demanding foundry applications.

7. Why Choose CO-NELE?

Since 1993, CO-NELE has specialized in industrial mixing technology, providing mixing equipment and customized process solutions for foundry, refractory, ceramics, powder metallurgy and other industries.

- More than 30 years of industrial mixing experience.

- Professional intensive mixing equipment manufacturer.

- Patented 3D printing sand mixing system.

- Customized heating and temperature control configurations.

- Integrated sand preparation and material feeding solutions.

- Laboratory testing and application-specific technical support.

8. Contact CO-NELE

Looking for an intensive mixer or integrated sand preparation system for foundry production and 3D sand printing?

Contact CO-NELE to discuss your sand characteristics, material formulation, production capacity and process requirements.

Our technical team can help evaluate a suitable mixing solution for your application.