The Fraunhofer Institute for Casting, Composite and Processing Technology (IGCV) has created an impressive work of art in miniature format: a detailed replica of the famous Munich Bavaria. The sculpture, unveiled shortly before the start of the Munich Oktoberfest, was created using additive manufacturing in 3D sand printing. It holds an oak wreath that was produced using a selective laser melting process.
New stack moulding process enables precise replication
Bavaria 2.0, an aluminium statue measuring one metre and weighing 25 kilograms, was produced using a new stack casting process. The process began with a detailed digital replica of the original, based on 3D scan data recorded in 2002 during the extensive restoration of the original. This made it possible to reproduce the historical monument in a miniaturised form with extraordinary accuracy and then divide it into 53 segments with the aid of simulation.
The casting mould itself was created using additive manufacturing in 3D sand printing and weighed an impressive 400 kilograms. For the actual casting, over 40 kilograms of aluminium were heated to over 750 degrees Celsius before being poured into the sand mould. After the casting process and cooling, all burrs were carefully removed from the work of art and it was polished.
Another challenge was the filigree oak wreath that Bavaria traditionally holds in her hand.
“Due to its fineness, the wreath could not be cast as well,” explains Dr Georg Schlick, Head of Additive Manufacturing at IGCV: “It would most likely have broken if the mould had been knocked off.”
This is where the selective laser melting process came into play, which formed the filigree object from molten, powdered metal layer by layer.
A successful milestone for foundry technology
For Dr Steffen Klan, Head of Foundry Technology at the IGCV in Garching, the successful casting is a highlight: “It's really something special when you can implement a new technology on a traditional model. With the successful casting, we were able to prove that it is possible to produce components of any size and complexity using the block size and the number of blocks.”
The original Bavaria is still the only walk-in large bronze in Germany and measures 18.52 metres from the base to the oak wreath. The miniature Bavaria now stands in the new Fraunhofer IGCV building in Garching and symbolises not only Bavaria's heritage, but also the institute's expertise and innovative strength.
The smaller version of Bavaria is sure to inspire not only visitors to the Fraunhofer IGCV, but also experts from all over the world.
