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Miniature of the Bavaria Statue – Innovation in Casting Technology
The Fraunhofer Institute for Casting, Composite, and Processing Technology IGCV has developed a scaled-down replica of the Munich Bavaria statue, utilizing an innovative stack casting process designed for producing complex components.
The Original Bavaria: A Technical Masterpiece Since 1850
The original Bavaria statue, which has stood over Munich's Theresienwiese since 1850, was designed by Ludwig Schwanthaler and remains a remarkable engineering achievement. The 18.52-meter-high statue is made of bronze, with much of the metal sourced from Turkish cannons sunk during the Battle of Navarino in 1827 and later recovered. The statue was cast in several stages and is still the only large bronze statue in Germany that can be entered by visitors.
Developing the Miniature: Digital Model and Stack Casting
Fraunhofer IGCV used 3D scan data collected during the 2002 restoration of the original Bavaria statue to create a digital model. This model was scaled down to a height of one meter. For the mold construction, researchers employed a stack casting approach, dividing the mold into 53 blocks, which were then produced using 3D printing.
The Casting Process: Aluminum Instead of Bronze
The casting process used aluminum, a lighter material than the original bronze. Around 40 kilograms of aluminum were melted at temperatures exceeding 750 degrees Celsius and poured into the prepared mold. After cooling, the mold was removed, excess material trimmed, and the surface of the miniature polished.
Additive Manufacturing for Fine Details
Due to the fragility of the statue’s intricate oak wreath, it was not feasible to cast it using traditional methods. Instead, selective laser melting (SLM) was employed to produce the wreath. This additive manufacturing process allows for the creation of complex geometries layer by layer from metal powder, without the need for a mold.
Exhibition at Fraunhofer IGCV
The completed miniature of the Bavaria statue is now displayed in the foyer of the new Fraunhofer IGCV building in Garching. It symbolizes the institute’s expertise and the possibilities of modern casting technologies.
Dr.-Ing. Steffen Klan
Head of Foundry Technology Department, Head of Casting Processes and Materials Department
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