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Honorable Mention


Accessories Plate Tooling & Equipment International, Livonia, Michigan


Material: A356. Process: Low pressure sand casting. Weight: 34 lbs. (15.4 kg). Dimensions: 31 x 14 x 6 in. (800 x 350


x 150 mm). Converted From: Integrates internal


cooling, air, fuel and accessories in power generators.


• The accessories plate casting is the largest casting in the Ecomotors opposed piston cyl- inder engine. It integrates the internal cooling and air management of the engine and provides mounting surfaces and precise geometry for the fuel system as well as the external accessory drives.


• The prototype component was produced in nine days, from start of engineering to first casting, with no tooling investment.


• According to the customer, TEI’s turnkey process eliminated the need for costly tooling during development cycles and costs were competitive with Asian and Indian sources with a much shorter lead time.


Honorable Mention Afocal Housing


O’Fallon Casting, O’Fallon, Missouri


Material: A356-T6. Process: Investment casting. Weight: 5.7 oz. Dimensions: 6.5 x 7.5 in. Converted From: Optics housing for a defense application.


• The part configuration features minimal wall thickness, undercuts, cored holes, lightening pockets, free standing bosses and complex internal features.


• The accuracy and repeatability of investment casting allowed the part to be designed with minimal stock allowances for machining and without consideration of draft.


• The casting design provides available gating surfaces, fillet radii and sufficient tolerance that lead to predictable yields and consistent metallurgy. O’Fallon Casting compression straightens each part to assure the dimensional consistency of the casting, guaranteeing the features are in the correct posi- tion for final machining.


April 2015 MODERN CASTING | 27


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