Mastering the Art of Casting

Casting Quality Factors

• Material properties, casting process, and design parameters influence the quality of a casting.

Design Considerations for Sand Casting

• Avoid sharp corners and intricate details due to the coarse grain size of sand.
• Design for easy removal of pattern and sand from the mold.

Design Considerations for Die Casting

• Design for thin walls and uniform sections to minimize shrinkage and porosity.
• Consider the high pressure and heat generated during the process.

Concerns for Sand Casting vs. Die Casting

• Sand casting is concerned with mold material strength, whereas die casting is not.

Successful Casting Practice

• Control of process variables, such as temperature, pressure, and time, is a condition for successful casting practice.

Benefits of Product Development Approach

• The approach does not provide a benefit of reduced cycle time.

Assembly in Manufacturing

• Assembly can represent up to 50% of the final product's cost.
• An important consideration for assembly is the ease of assembly and disassembly.

Cradle-to-Cradle Production

• Cradle-to-cradle production is a design approach that considers the entire product lifecycle, from creation to reuse or recycling.
• Three main points of cradle-to-cradle production are:
  • Use of technical and biological nutrients
  • Design for disassembly and recyclability
  • Closing material loops through recycling and reuse