There are a number of steps we take in the casting process that are not typical of the “average” prototype or production foundry. We combine the project information you on the “Request A Quote” form with an analysis of the CAD models and prints (if provided) to evaluate the “castability” of a given geometry.
The more complete your information is, the better we can help you find optimal solutions to your prototyping and production challenges. We look beyond your immediate needs and try to incorporate features that will be required by your production process.
Our value-added activities include, but are not necessarily limited to, the following actions by our highly-experienced casting engineers:
Casting geometry is analyzed for its level of general manufacturability
CAD that is submitted with the RFQ is “validated” regarding its ability to be used for the production of the casting
- Is the CAD a true solid that can be “cavitied”?
- Is the CAD scaleable?
Draft analysis is performed. Missing draft, inconsistent draft, undercuts, and design “oversights” are noted and captured in a report that is sent to the Customer.
Cross-sectional analysis is performed to ensure that there is the proper thickness for the casting process selected and the machining operations.
Design recommendations are noted and communicated with the Customer.
The need for cores, slides, inserts, etc. is established
On especially difficult geometries we often perform a foundry FEA analysis that simulates our casting process. This simulation highlights potential trouble areas in the casting
Prints/Drawings provided are reviewed and evaluated for:
- Critical-to-Function (CTF) items
- Features that fall within/outside of our casting and machining processes
Tolerances
- Appropriate?
- Achievable?
We create a color-coded version of the CAD that provides clarity by differentiating items like as-cast features, machined features, and features affected by rigging, chills, etc.
Once we receive a project we review the information available from the quoting process and perform a more in-depth analysis, if required.
We analyze each casting with true production application intent. Simulating castings destined to be mass produced in die-casting, permanent mold casting (gravity die-casting), investment casting and sand casting is why we are here. We endeavor to make our prototypes and limited production casting indistinguishable from the final production units (within the limits of our processes) to maximize their value and utility to you, our Customer. These aren’t one-offs or shown-and-tell parts. They are production quality parts delivered to you in rapid-prototype-turnaround times.
Contact us if you have any questions.