lead time around that,” he said. “And anytime we get an updated forecast, we communicate that to the suppliers. When we partner with someone, we are very open as far as numbers we are going to need.” Tis openness continues through the engineering and design stages of product launch. Trough the proto- typing phases of the diecast motor enclosure mount, engineers at BAF worked closely with the casting sup- plier to make adjustments through the initial prototype, soft tool and hard tooling phases. “On new projects, engineering works with us in advance to make sure the designs are feasible. Once the product line is in production, the engineering team is always ready to assist us with any quality and productivity improve- ments that we may want to implement,” Preuss said. “Tey understand our pro- cesses and are always open to new ideas to help us make a better casting.” Te result for the enclosure was a
more sophisticated part, Oleson said. “We adjusted the shape of the
curve, the details on the inside of the cap, and the cross-hatchings on the lid,” he said. “Our suppliers know their process better than us, so it is not uncommon for them to make recom- mendations to improve the function or manufacturability. Te earlier diecast part we made was not as complex.” Te volumes and speed to produc-
tion required by BAF steered the company to diecasting, but it had used sand cast and permanent mold cast components for a time in earlier years. You’ll still find some sand cast- ings in the gearboxes the fan maker buys from a local manufacturer. But for the most part, BAF uses alumi- num and sometimes zinc die castings and this use will likely grow, O’Brien said, as the company continues to rapidly expand further into the com- mercial and residential markets, as well as lighting. “I think we’ll continue with a
strong need for castings in the future, because of the finishing capabilities, as we are getting into custom-type product lines,” O’Brien said. “It’s going to just continue to grow.” ■
Your Source for Aluminum Sand Castings
Now Producing
Low Pressure Permanent Mold Castings
In House:
Heat Treating X-Ray
CNC Machining Finishing
Lab Services Testing
Certifi cations ISO 9001:2008
Richard Oleson, senior design engineer at BAF, demonstrates how two die castings are placed together in a fan’s motor housing.
www.littlestownfoundry.com
Littlestown PA 17340 • 800-471-0844
customerservice@littlestownfoundry.com
Doing It Right since 1916
Jan/Feb 2016 | METAL CASTING DESIGN & PURCHASING | 23
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