Energy and Power Casting — From GIS Shells to Turbine Housings
3DPTEK delivers precision castings for the energy sector using 3D printed sand molds, low-pressure casting, and gravity casting. From 126KV to 1100KV GIS shells to hydroelectric impellers — prototype in as fast as 5 days, serial production at 200 plus sets per month. Trusted by Pinggao Group, Korea LS, and Korea ILJIN.
What We Cast for Power Generation
From high-voltage transmission to hydroelectric and nuclear power, our 3D-printed sand mold technology eliminates tooling costs and compresses lead times. Every component meets Class I casting quality standards.
GIS Shells
126KV to 1100KV GIS shells with 0-defect sealing surfaces, SF6 gas-tight, passed helium leak detection. Prototype in 5-7 days.
Turbine Housings
Steam and gas turbine housings in cast iron and stainless steel. Complex internal cooling passages, integrated molding.
Hydro Components
Impellers, runners, and pump bowls for hydroelectric power plants. Cast iron HT250 with CT7 dimensional accuracy.
Nuclear-Grade Parts
Pump casings, valve bodies, and shielding components. Full NDT suite: UT, radiography, penetrant testing. ISO 9001 certified.
Energy Casting Components We Deliver
Every energy application has unique requirements. Here is the full range of power-generation castings we produce -- each with proven processes, qualified materials, and documented case studies.
GIS Shell Castings (126KV - 1100KV)
Gas-insulated switchgear shells are our flagship energy product. We use 3DP sand molds for rapid prototyping (5 to 7 days per set), then transition to metal mold low-pressure casting for serial production at 200 plus sets per month. Every shell passes helium leak detection, X-ray inspection, and air-tightness testing. Zero defects required on sealing surfaces -- a standard we have consistently met for Pinggao Group, Korea LS, and Korea ILJIN.
Turbine Housing Castings
Steam turbine and gas turbine housings with complex internal volute geometries. 3D printed sand cores enable integrated molding of intricate cooling channels that are impossible with traditional pattern-making. Materials: cast iron HT250, ductile iron, stainless steel.
Hydroelectric Impeller Castings
Impellers with right-angle blade connections and complex internal cavities. Our 3DP sand mold + gravity casting process achieves CT7 dimensional accuracy and Ra12.3 surface quality. 20-day delivery for 4 sets of blanks -- 80 percent faster than traditional tooling-based methods.
Generator Component Castings
End covers, bearing housings, and water-cooled motor housings for large industrial generators. Our water-cooled motor case (550x440mm, 43KG, aluminum alloy) features complex spiral cooling channels between inner and outer walls -- integrated molding in a single pour.
Nuclear-Grade Pump Casings
Pump casings and valve bodies requiring full NDT documentation: ultrasonic testing, radiography, magnetic particle inspection, and dye penetrant. 3DPTEK operates to Class I casting quality standards with complete material traceability and certified test reports.
High-Voltage Electrical Components
Tanks, shielding covers, and conductor enclosures for high-voltage substation equipment. ZL101A aluminum alloy with low-pressure casting ensures uniform density and conductivity. 200 sets per month batch delivery with full machining and testing.
Wind Power Components
Large structural castings for wind turbine hubs, nacelle frames, and pitch control housings. Our J4000 sand 3D printer handles build volumes up to 4000×2000×1000mm -- enabling single-piece sand molds for meter-scale wind energy components.
From Your CAD to Certified Energy Castings in 4 Steps
One engineering team manages your project end-to-end — DFM review, 3D-printed sand molds, casting, full NDT, and finish machining. No pattern shop handoffs, no re-qualification surprises.
Send CAD & Get DFM Review
Upload your 3D model or 2D drawing. Our engineers return a feasibility analysis, recommended alloy and process — usually within 24 hours.
3D-Printed Sand Mold
We print the mold and core directly from your model on our own 3DP and SLS sand printers — no tooling, no pattern shop, prototype in 5 to 7 days.
Pour, NDT & Certify
Low-pressure or gravity casting in our own foundries, then in-house X-ray, UT, MPI, dye penetrant, and helium leak testing with full reports.
Machine & Ship
Finish machining, surface treatment, dimensional inspection, and documentation — then we ship to your site or assembly line, on schedule.
Prototype in 5-7 days, serial production at 200+ sets/month. Send us your drawing →
Energy Sector Case Studies
Real projects, real results. These case studies demonstrate our proven capability in energy and power generation casting -- from rapid prototypes to serial production.
126KV to 1100KV GIS Shell
| Material | ZL101A Aluminum Alloy |
| Process | 3DP Sand Mold + Low-Pressure Casting |
| Prototype Cycle | 5 to 7 Days / Set |
| Serial Production | 200+ Sets / Month (Metal Mold LP Casting) |
| Quality | Helium Leak Detection, X-Ray, Class I Casting |
SF6 gas encapsulated. Zero defects on sealing surfaces -- pinhole tolerance less than or equal to 1. Passed air-tightness test and full flaw detection. Transitioned from prototype to serial production using the same engineering team throughout.
Hydroelectric Impeller
| Material | Cast Iron HT250 |
| Process | 3DP Sand Mold + Gravity Casting |
| Cycle | 20 Days / 4 Sets of Blanks |
| Accuracy | CT7 Dimensional, Ra12.3 Surface |
| Key Challenge | Right-angle blade connections, complex cavity |
The impeller features blades at right angles to each other with a complex internal cavity structure. Traditional casting had low yield and high cost. 3DP sand mold + gravity casting achieved integrated core molding, reducing cost and improving consistency.
Substation Tank and Shielding Cover
| Material | ZL101A Aluminum Alloy |
| Process | 3DP Sand Mold + Low-Pressure Casting |
| Tank Size | 800 x 600mm |
| Shielding Cover | 650 x 150mm |
| Production | 200 Sets/Month, Fully Machined |
Both tank and shielding cover meet Class I casting standards, with full machining and conductivity testing. 20-day delivery for finished products. The shielding cover passed conductivity requirements for high-voltage applications.
Water-Cooled Motor Housing
| Material | Aluminum Alloy |
| Size | 550 x 440mm, 43KG |
| Process | 3DP Sand Casting |
| Key Feature | Integrated spiral cooling channel, thin wall |
| Result | Better density than traditional casting |
Currently the largest power motor shell in China for new energy trucks. Complex spiral cooling channels between inner and outer walls require integrated molding. 3DP sand casting achieved single-pour manufacturing with superior density and pressure-bearing capacity.
From R and D to Serial Production -- One Partner
Unlike prototyping-only services, 3DPTEK is an equipment manufacturer AND a casting service provider. We use our own printers for prototyping and transition seamlessly to metal mold production.
Manufacturing Centers Across China
Industrial 3D Printers Installed
Years in Rapid Prototyping and Casting
Patents, 3 National Standards
Alloys for Energy Applications
We cast 6 alloy families for the energy sector. Every material batch is qualified with composition analysis and mechanical property testing before production begins.
| Alloy Family | Typical Grades | Key Property | Casting Process | Energy Use Cases |
|---|---|---|---|---|
| Aluminum Alloy | ZL101A, A356, T6061 | Lightweight, conductive | Low-Pressure, Gravity | GIS shells, tanks, motor housings, shielding covers |
| Cast Iron | HT250, HT300 | Damping, machinability | Gravity, Sand Casting | Impellers, pump bodies, turbine housings, reducer housings |
| Ductile Iron | QT400-18, QT500-7 | Strength + toughness | Sand Casting, Gravity | Wind turbine hubs, generator frames, large structural parts |
| Stainless Steel | 304, 316, 17-4PH | Corrosion resistance | Investment, Sand Casting | Nuclear pump casings, valve bodies, turbine housings |
| Superalloys | Inconel 718, Hastelloy | High-temp strength | Investment Casting, SLM | Gas turbine hot-section components |
| Cast Steel | ZG25, ZG35CrMo | Weldable, tough | Sand Casting, Gravity | Generator end covers, bearing housings, structural frames |
Sand 3D Printers That Make It Possible
We design and build the printers, then use them to cast your parts. No one understands the technology better than the manufacturer.
3DPTEK-J4000
Build volume up to 4000×2000×1000mm — single-piece molds for meter-scale GIS shells and turbine housings.
3DP Sand · 400dpi View Full Specs →
3DPTEK-J2500
Build volume 2500×1500×1000mm at 650 L/h — high-throughput serial mold production for medium castings.
3DP Sand · 650 L/h View Full Specs →
3DPTEK-J1800
Build volume 1800×1000×700mm — agile platform for R and D iterations and small-batch energy parts.
3DP Sand · Compact View Full Specs →
LaserCore-5300
SLS sand cores with 4-6 MPa strength for complex turbine cooling channels and pipeline castings.
SLS Sand & Wax View Full Specs →Quality Assurance and Certifications
Energy components cannot fail. Our quality systems are built for zero-defect delivery.
ISO 9001, ISO 45001, ISO 14001
Triple-certified quality management, occupational health, and environmental systems. Regularly audited by Pinggao Group, Korea LS, and ILJIN.
Full NDT Suite In-House
X-ray, ultrasonic testing, magnetic particle inspection, dye penetrant, helium leak detection, and hydrostatic pressure testing -- all performed in-house.
Class I Casting Standard
All energy-sector castings are produced to Class I quality standards. CMM dimensional inspection with full reports delivered with every batch.
Complete Material Traceability
Every pour is documented: heat number, composition analysis, mechanical test results, and NDT reports -- all archived for the life of the program.
Energy Industry Leaders Rely on 3DPTEK
Our energy-sector customers include leading high-voltage equipment manufacturers and power generation OEMs.
Energy and Power Casting FAQ
5 to 7 days per set using 3DP sand molds. No tooling is required -- we print the sand mold directly from your 3D model and pour the same week. This is how we support Pinggao Group rapid product iteration for 126KV to 1100KV GIS shells.
Yes -- this is our proven model. We use 3DP sand molds for R and D and qualification, then transition to metal mold low-pressure casting for serial production at 200 plus sets per month. The same engineering team manages quality throughout. No re-qualification needed when switching processes.
Full suite: X-ray radiography, ultrasonic testing, magnetic particle inspection, dye penetrant testing, helium leak detection (for GIS shells), and hydrostatic pressure testing. All performed in-house. Reports are delivered with every batch.
ISO 9001:2015, ISO 45001:2018, ISO 14001:2015, CE, and EAC certifications. We are Pinggao Group strategic supplier and the exclusive China GIS shell supplier for Korea LS and ILJIN -- our quality systems are regularly audited by these multinational customers.
Our J4000 sand 3D printer builds molds up to 4000×2000×1000mm, enabling single-piece sand molds for meter-scale components. For even larger parts, we use segmented mold assembly. Our foundries handle castings from a few kilograms to several tonnes.