Christie projectors are used for a wide variety of end uses, from showing 3D movies in theaters to presenting lesson plans in classrooms.


digital cinema and corporate presen- tations, Christie uses a number of materials and processes for its castings. Larger components— for example, the baseplates that support units weighing as much as a 280 lbs. —are sand cast in either stainless steel or aluminum. Casting these components reduces cost versus high-precision welding and machining. Compared to those machined from stock, the cast metal components off er improved mechanical and physical properties at a reduced cost. Within the projectors, a number of


components must meet high standards for form, fi t and functionality. T e lens mount, for example, could produce myriad technical problems if it did not meet exact standards.


“ “High precision is essential to the


function of Christie’s projectors,” said David Kiers, director of engineer- ing at Christie. “Critical features are machined after casting to hold tighter tolerances when required.” Many other applications, such as


those related to the projector’s proces- sors and microchips, require much smaller components with signifi cantly diff erent design considerations. In ad- dition to aluminum, steel and magne- sium, zinc is used for applications with lower weight considerations. In total, Christie uses components


produced via diecasting, permanent mold, sand and investment casting processes. When identifying a possible candidate for conversion to a casting process (or redesigning an existing


Christie aims to incorporate metalcasting facilities early in the design process. Identifying and eliminating problems early can streamline progress and limit design iterations.” —JIM STEWARD, COMMODITY MANAGER


38 | METAL CASTING DESIGN & PURCHASING | Jan/Feb 2015


casting), the selected process is based upon many factors including cost, expected volumes, choice of materials, degree of complexity, visual cosmetics and fi nal appearance. Engineering must overcome two


traditional barriers to develop a conceptual design to obtain a cost- eff ective, feasible casting. T e fi rst challenge is developing a relation- ship with metal casting suppliers that encourages and fosters early, eff ective and ongoing communication. “Christie aims to incorporate


metalcasting facilities early in the design process. There’s a high level of collaboration,” said Jim Stew- ard, Christie’s commodity manager. “Identifying and eliminating prob- lems early in the process can help streamline progress and control costs by limiting design iterations.” T e second challenge is inherent in the supplier-customer relationship, with the two engineering teams having to marry diff erent considerations in a part’s fi nal design. “Typically, the product designer


is focused on issues such as the part functionality, operating environments, failure modes, secondary operations and cosmetics,” said Mark Ratcliff e, manu- facturing engineer. “T e engineers who will design the casting and its tooling,


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