• Maximum machine precision with short processing times
  • Design on the outside – technology on the inside
  • Economical for large and small series

Nanodur® revolutionises mineral casting technology

Nanodur® flows into the formwork like honey

Your advantage in mechanical engineering: mineral casting beds can be moulded more easily and therefore more economically than before.

Deaerates and compacts itself
The innovative high-performance material Nanodur® moulded complex and solid components for the machine industry. Nanodur® stands for a cement-bound mineral casting, developed through many years of research in the nano range by technology partner and binder manufacturer Dyckerhoff. In contrast to epoxy resin-bonded mineral casting, the mould does not need to be vibrated during filling so that the material is distributed and compacted; Nanodur® flows, deaerates and compacts by itself. Thanks to the good workability, inexpensive and quickly procurable timber or plastic formwork is often sufficient; Steel can only be used if the formwork is extremely durable and precise

High-performance material for technology and nature

Recipe for sustainable high-performance material in modern high-tech mechanical engineering

Sand, premium cement of the latest generation, water and small quantities of two liquid additives for better processing;

Optimised for maximum packing density
The cast stone is optimised with nanotechnology for maximum packing density, which can be seen with the naked eye from the smooth surface; It can be completely coloured through or painted afterwards;

Environmentally friendly processing
Ein vom deutschen Bundesministerium für Bildung und Forschung gefördertes Projekt hat ergeben, dass Nanodur® einen deutlich günstigeren ökologischen Fussabdruck hinterlässt als epoxidharzgebundener Mineralguss. No solvents are required for processing, as water is sufficient for cleaning the tools

Climate protection and problem-free disposal of old machines
The production of Nanodur® consumes less energy and emits less CO2 than with epoxy resin-bonded mineral casting. Nanodur can be reused in crushed form as a bulk material in road construction or as grains in recycled concrete thanks to its purely mineral composition.

A comparison of different materials for machine beds

Nanodur® (zementgebundener Mineralguss)Epoxidharz-gebundener MineralgussGranitGrauguss (Gusseisen mit Lamellengrafit)
Dichtekg/dm³2.4–2.52.0 – 2.52.5 – 3.07.1 – 7.3
DruckfestigkeitN/mm²125–13590 – 150160 – 240600 – 960
BiegezugfestigkeitN/mm²18–2015 – 3510 – 30150 – 400
E-ModulkN/mm²45–5020 – 4540 – 6080 – 140
Längenausdehnungskoeffizientμm/(m·K)10–1110 – 205 – 1110 – 13
WärmeleitfähigkeitW/(m·K)2.8–3.21.5 – 2.01.7 – 3.547 – 53
Spezifische WärmekapazitätJ/(kg·K)750 – 1’000750 – 1’000750 – 1’000460 – 540

Precision to the power of three

Geometric precision
We use precise moulds to cast raw bodies with a surface accuracy in the tenths of a millimetre range; Tempering the hardened material results in excellent dimensional stability Progressive setting processes of the cement and the associated shrinkage deformations are stopped by tempering; Accuracies with flatness in the μm range are achieved by reworking the hardened blanks; Either stone grinders bring contact surfaces to size so that add-on parts such as steel rails can then be precisely attached, or metalworkers machine cast-in steel components directly to the desired final dimensions;

Steel component moulded in Nanodur® with metalworking tool
The highest precision is often required at contact points between the machine bed and add-on parts, which requires steel or stone finishing of the raw body;

Vibration behaviour in comparison

Vibration behaviour in comparison
The graphic shows that Nanodur® compared to grey cast iron and dampens vibrations much faster.

Dynamic precision
Interfering vibrations from machine movements must be effectively damped by the machine bed; The damping performance of Nanodur® is comparable to natural stone or epoxy resin-bonded mineral casting – up to ten times better than grey cast iron.

Conclusion: Maximum precision combined with fast machining speed, noise reduction and extended tool life.

Thermal precision
Nanodur® reacts much more slowly to thermal energy than grey cast iron due to its high specific heat capacity and low thermal conductivity. Inaccuracies caused by room temperature fluctuations are significantly smaller due to the material-related thermal inertia; In order to actively control thermal deformations from process heat as well as external and internal heat sources, heating or cooling lines can be moulded into the solid machine bed;

Temperature stability

Temperature stability
Thanks to the thermal inertia of Nanodur®, fluctuating room temperatures are only passed on to the machine to a very limited extent.

Cost savings in mould making

Engineering and design in harmony

Good news for machine manufacturers
Your brand gains recognition value. This is thanks to an attractive, unique design. Expand the technical form into a consistent brand design and strengthen your position in the market. We advise you on the creative freedom and realise the potential of the self-compacting flowing compound in production with intelligent formwork construction;

Artificial stone with reproducible properties
The purely mineral casting compound hardens at ambient temperature without the addition of energy to form artificial stone with reproducible mechanical and physical properties; Just as in natural stone technology, smaller individual parts can be bonded together to form a larger whole for very complicated shapes;

Economical even for small batches and heavy machine beds
Thanks to the lower fixed costs for mould construction, the advantages of mineral casting technology can be used economically even for small series. The material costs for Nanodur® are lower than for epoxy resin-bonded mineral casting; This cost advantage is particularly evident in the unit price of large and heavy machine beds; In addition, unlike steel and oil, this inexpensive material is not affected by fluctuations in world market prices;

Technology neatly embedded
In the cold casting compound, you integrate components (rails, anchor plates, threaded sleeves, transport anchors, hydraulic lines, earthing, cables, plastic conduits) into the machine bed in a compact and visually appealing way. The frost-resistant mineral casting is non-combustible and therefore resistant to flying sparks; Therefore, steel parts can also be welded onto the hardened machine bed on cast-in anchor plates at a later date;

Bed rest with numerous applications

  • Metal and woodworking machines
  • Textile machinery
  • Packaging machines
  • Pick & place applications
  • Graphic machines
  • Optical industry
  • Laser industry
  • Electrical industry
  • Measurement technology
  • Solar technology
  • Medical technology

A strong foundation

Maximum production – minimum interfaces
Not only for people, but also for machines: a good bed is the basis for a successful day’s work. We have therefore set ourselves the challenging task of developing and producing high-precision machine beds and tool frames. By working closely with qualified partner companies, Frei Engineering can offer you a complete service from dimensioning, body shell production, measuring, painting and partial assembly to precise finishing by steel or stone grinders; for you, this ultimately means: maximum production – Minimal interfaces.