Mickaël Dernoncourt - Using advanced manufacturing to recreate a classic engine block
| Friday, October 9, 2026 |
| 2:00 PM - 2:30 PM |
| Norfolk Room |
Speaker
Mr Mickaël Dernoncourt
Key Account Manager
Metcast Services
Using advanced manufacturing to recreate a classic engine block
Synopsis
Advanced manufacturing technologies are creating new opportunities for foundries to produce complex, low-volume and legacy components without the significant investment traditionally required for patterns and core tooling.
This presentation follows the engineering journey undertaken to manufacture an engine block using 3D printed sand moulds and cores.
The project began with the development of the 3D CAD model, followed by design modifications to optimise the component for casting and additive manufacturing. The casting method was then developed using traditional foundry principles combined with modern digital tools, including gating and feeding design, methoding and casting simulation.
Simulation played an important role throughout the development process, allowing metal flow and solidification behaviour to be evaluated, potential defects to be identified, and design modifications to be assessed before committing to production. The final mould and core package was then manufactured using 3D sand printing, providing a direct route from digital design to the foundry floor without conventional tooling.
Through this case study, Metcast will demonstrate how the combination of practical foundry expertise, 3D design, casting simulation and additive manufacturing can provide innovative solutions for complex prototypes, legacy components and low-volume castings.
Ultimately, while 3D sand printing removes many of the traditional limitations of patternmaking, successful castings still rely on good foundry engineering.
This presentation follows the engineering journey undertaken to manufacture an engine block using 3D printed sand moulds and cores.
The project began with the development of the 3D CAD model, followed by design modifications to optimise the component for casting and additive manufacturing. The casting method was then developed using traditional foundry principles combined with modern digital tools, including gating and feeding design, methoding and casting simulation.
Simulation played an important role throughout the development process, allowing metal flow and solidification behaviour to be evaluated, potential defects to be identified, and design modifications to be assessed before committing to production. The final mould and core package was then manufactured using 3D sand printing, providing a direct route from digital design to the foundry floor without conventional tooling.
Through this case study, Metcast will demonstrate how the combination of practical foundry expertise, 3D design, casting simulation and additive manufacturing can provide innovative solutions for complex prototypes, legacy components and low-volume castings.
Ultimately, while 3D sand printing removes many of the traditional limitations of patternmaking, successful castings still rely on good foundry engineering.
Biography
Mickaël Dernoncourt is originally from France and moved to New Zealand in 2014 after completing a Master’s degree in Mechanical Engineering, specialising in Foundry Engineering. He brings more than a decade of New Zealand experience across foundry engineering, metal casting, and manufacturing, with expertise in casting process design, simulation, product development, and technical sales.
In his role with Metcast, Mickaël works closely with customers across the foundry, engineering, and manufacturing sectors. He provides practical technical solutions spanning melting and refractory products, additive manufacturing consumables, and process optimisation. Combining strong engineering knowledge with a commercial focus, he helps manufacturers improve quality, productivity, and profitability through value-driven solutions. He is also passionate about innovation, AI-driven business automation, and identifying opportunities to strengthen New Zealand’s manufacturing industry.
