Selection of aluminum casting process 1

[tgmcg]

Hi,

I have some very basic questions and will appreciate any and all help. We're tooling up for production of a new product we've developed. The product can be seen at (

http://www.tailboats.com)

There are three of four major aluminum parts that should probably be made using some form of casting technology. The largest part runs approx 12" x 3" x 6". Fatigue resistance, corrosion resistance and tensile strength are primary considerations. The parts will require some finish machining operations after casting and will then be powder coated.

We'll be ordering the parts in batches of less than 50 parts each.

I'm not clear on the relative technical and cost benefits between the various casting processs...eg. permanent mold, investment casting and die casting.

What casting processes should we be considering first? What kind of tooling and production costs should we expect...order-of-magnitude? Do you have any recommendations as to who we might contact?

Thank you for your help.

Best regards,

Tom

 

[cancsco]

Hello all,
I would strongly vole for the investment casting for a batch of 1000 pcs as the costs involved in the tooling and the production are less. Also this would be the best for little after machining operations (good Surface finish).

 

[tgmcg]

Unclesyd,

Thank you. You are a storehouse of knowledge. I will contact the folks at Port Shell Molding and Cubic.

The metal spray mold-making process of Cubic is of particular interest. I've been looking for a mold-making technology for injection molded parts that could significantly reduce tooling costs, which is a major hurdle for the introduction of any new product. Their metal spray process looks like a possibility. Simpler than SLA/SLS.

The Port Shell molding process may also suit a couple of our parts particularly well.

Best regards,

Tom

 

[tgmcg]

Cancsco,

We have not ruled out investment casting as a possibility. The product has several parts, and it is likely we will employ a number of different casting and molding processes.

Functionality and cost are the main drivers. If there's a lower cost process or material that provides the required functionality, we'll go with it.

One downside of all this is that there are so many different options to choose from, yet there is not very much info on the relative costs for each option. This necessitates a lot of budgetary quoting.

I suppose it would be helpful if there were vendors who could provide competitive bids for supplying all the parts per processes of their own recommendation. We would provide specs, design drawings and applied loads for each part detailing features required for functionality. The vendor would select a manufacturing process for each part and refine each part design for manufacturability (shelling, ribbing, etc). The manufacturing of each part may be vendor in-house or outsourced. In this manner, we could more effectively draw on the accumulated expertise of those who are more intimately familiar with the various technologies. The vendor proposing the lowest cost, technically compliant "package" would get the job. Is such an approach common in the casting and injection molding industry? I suppose a strategic alliance of some sort could accomplish the same.

Best regards,

Tom

 

[arunmrao]

Mcguiness,
As your batch quantities are rather small , the process of manufacturing not defined and the technical delivery condition not in place large units having the expertise and means might shy away from quoting. The smaller ones would be keen to supply but will need all the technical inputs from you. I suppose this must have been your experience.

Most often the foundries adopt the safe and mean path by asking the customer to define all the parameters and freeze the drawing. There is also the big question of product liability in the event of a failure.(Many unpleasant issues will arise!!)

This problem to some extent can be handled by independent consultants and designers who have their network around the industry. Academics may not be successful in this aspect.

 

[bobdz]

We work with alot of aluminum casting guys of all types.
Sounds like sand would be best, there are precision sand guys, a356 is probably the best. Let me know if you need some names of good foundries. we could even get you several quotes. Send me a drawing