At the right production quantities it is simply impossible to beat the cost advantages of metal casting. Not only that, cost reductions can be had using this process due to the potential to integrate an assembly of parts into a single unified components. Out go fasteners, labor, quality issues and more. Beyond that, casting allows for the expression of design ideas and techniques impossible to achieve (at the same cost) through other means. Some of the parts on this image show features that would require either multiple individual CNC parts bolted together, very complex 5 axis machining, or both.
Of course, every process has it’s advantages and disadvantages. Depending on specifications, casting might not be able to deliver the required required accuracy and precision. This is where the design of parts and molds for casting becomes important.
The first pass design of a casting meant for an application requiring specific levels of accuracy and precision is to design the mold to be “safe”. By this we mean that a mold is designed such that additional adjusting cuts can be made in order to progressively approach the required manufacturing specifications. One would also modify the parts to be cast such that post-processing through CNC machining can be used to improve process variables.
A simple example of the latter would be a pattern of accurately placed holes with specific diameter tolerances. Now we have the dynamics of hole-to-hole distances as well as the relationship of the entire pattern with respect to the part or a reference datum on the part (for example, the central shaft bearing hole or seat in the case of a casting for a motor enclosure). A design that makes allowances for fine-tuning features post-casting will always provide a conduit for highly integrated cost-reduced parts while retaining the important accuracy and precision characteristics of conventional CNC machining.
Our manufacturing partners can bring a range of technologies to your design in order to help improve quality and yields and reduce costs:
- Infrared thermal management
- Software Flow Simulation
- Computerized programmable tilt and pour systems
- Sub-gating
- Inserts
- Die Casting
- Sand Casting
- Investment Casting
- Aluminum casting to 38,000 PSI tensile strength
- Options on surface smoothness
- Thin and thick wall parts
- Close tolerance control
- Better surface finish
- CNC post-processing