Redefining Foundry Efficiency and Sustainability: The Rise of Starch-Based 3D-Printed Molds and Cores

At CastExpo 2025, LightSpeed Concepts unveiled a transformative approach to sand casting: starch-based 3D printing of molds and cores. This innovative technology is poised to reshape foundry operations by enhancing sustainability, simplifying workflows, and unlocking new design possibilities. Backed by decades of development in sand 3D printing, this new binder system—branded BlueNano®—marks a breakthrough in making additive manufacturing more accessible, environmentally friendly, and economically viable.

The Problem with Traditional Binder Systems

While 3D sand printing has revolutionized the way foundries think about core and mold production, adoption has been hampered by limitations in binder chemistry. Furan-based binders, once a go-to solution, have been plagued by environmental, health, and safety concerns. Inorganic binders, though more eco-conscious, introduce complex processing challenges and compatibility issues with certain casting alloys.

Despite its clear advantages in reducing lead times, tooling costs, and geometric limitations, these limitations have kept many foundries from fully embracing additive manufacturing.

BlueNano®: A Simple System for Complex Castings

Enter BlueNano®, LightSpeed’s starch-based binder designed specifically for 3D printing. This binder offers a practical alternative that delivers both operational simplicity and sustainability. Here’s how:

• Sustainable Sourcing: Starch is plant-derived and renewable, making it a fundamentally greener alternative to petroleum-based binders.

• Safer and More Agile Operations: BlueNano® is non-hazardous, low-odor, and aligns with modern EH&S priorities. Its low toxicity improves workplace conditions and reduces compliance burdens.

• Efficient Printing Process: Unlike traditional systems that require extensive post-processing, BlueNano® eliminates the need for acid mixing and intensive cleaning. Depowdering is simple and fast.

• Closed-Loop Reclamation: Its sand-agnostic nature and low-temperature reclamation capabilities support sustainable, circular foundry operations.

Productivity Meets Design Freedom

One of the most compelling features of BlueNano® is how it empowers foundries to design and build more complex castings with fewer process constraints. With no need for post-processing and significantly reduced defect rates, this binder system enables:

• Quick iteration cycles

• Low-labor workflows

• New design features that were previously impractical or impossible

Whether it’s intricate cores, undercuts, or assemblies that previously required multiple tooling steps, BlueNano® makes complex casting simpler and faster.

Triple Bottom Line Benefits

LightSpeed’s approach is grounded in the triple bottom line framework, delivering value across people, planet, and profit:

• People: BlueNano® supports Industry 4.0 integration while reducing operator exposure to hazardous substances.

• Planet: Its closed-loop reclamation and plant-based formulation minimize waste and energy use.

• Profit: Foundries benefit from higher throughput, fewer defects, and compatibility with a wide range of sand types—without costly machine or process upgrades.

Future Outlook: Expanding the Binder Frontier

The development of starch-based binders is part of a broader evolution in foundry materials. New combinations of organic and inorganic components and the use of non-toxic chemical crosslinkers are opening up opportunities for even stronger and more humidity-resistant molds and cores.

BlueNano® leads this wave of innovation by being one of the first starch-based binders tailored specifically for 3D printing—uniting environmental goals with the performance demands of modern foundries.

Contact Us

Our team is excited to discuss how your foundry can benefit from the latest in starch-based 3D printing technology.

Want to speak with us directly? Contact Daniel Shirkey at (517) 908-8542 or daniel.shirkey@lightspeedconcepts.net.