ACTech GmbH of Freiberg/Germany, a leading developer and manufacturer of casting prototypes, is about to broaden its portfolio. From mid-2008 the company will also produce cast parts of nickel-based alloys using rapid prototyping. With this step, ACTech is responding to the growing demand from the aviation and aerospace industry. Nickel-based alloys are very heat resistant and resilient, making them ideal for aircraft engine parts which are highly thermically stressed. To date, manufacturers and Tier 1 suppliers in this segment have faced a global shortage in subcontractors, as the casting of nickel-based alloys involves an extremely sophisticated technological process. To use rapid prototyping with these particular alloys, special smelting technologies are needed. In addition, casting and feed systems have to be geared to the specific materials. The subsequent heat treatment, material testing and mechanical processing also make special demands in terms of technique, technology and know-how. In casting nickel-based alloys, ACTech can draw on its vast project experience with rapid prototyping for the aviation and aerospace industry. At the same time, ACTech works closely with the Foundry Institute of the Technical University of Freiberg, which has extensive expertise in this sector.

ACTech frequently participates in development projects for the aviation and aerospace industry, producing for companies such as MTU Aero Engines, ZF-Luftfahrt, Airbus, Thielert Aircraft Engines as well Hispano Suiza and Techspace of the Snecma Group. Components typically supplied for aviation and aerospace include, for instance, engine parts or gear and oil pump housing. When developing prototypes for customers, ACTech is in a position to make considerable time gains by laser-sintering Croning mould materials and applying other mould production techniques from the field of rapid prototyping. Besides the start-to-finish production of flight-capable prototypes, testing these prototypes is also part of ACTech's spectrum of services and products. "Given that so many of our customers are engaged in the aviation and aerospace industry, it is only consistent that we broaden our portfolio by also offering the casting of nickel-based alloys," comments Bodo Manz, sales engineer at ACTech responsible for the aviation and aerospace sector.