Christie projectors are used for a wide variety of end uses, from showing 3D movies in theaters to presenting lesson plans in classrooms.
in a wide range of end uses, such as 3D digital cinema and corporate pre- sentations, 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 offer improved mechanical and physical properties at a reduced cost. Within the projectors, a number of
components must meet high standards for form, fit and functionality. Te 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 engi- neering at Christie. “Critical features are machined after casting to hold tighter tolerances when required.” Many other applications, such
as those related to the projec- tor’s processors and microchips, require much smaller components with significantly different design considerations. In addition to alu- minum, steel and magnesium, zinc is used for applications with lower weight considerations. In total, Christie uses com-
ponents produced via diecasting,
permanent mold, sand and invest- ment casting processes. When identifying a possible candidate for conversion to a casting process (or redesigning an existing cast- ing), the selected process is based upon many factors including cost, expected volumes, choice of mate- rials, degree of complexity, visual cosmetics and final appearance. Engineering must overcome
two traditional barriers to develop a conceptual design to obtain a cost-effective, feasible casting. The first challenge is developing a relationship with metal cast- ing suppliers that encourages and fosters early, effective and ongoing communication. “Christie aims to incorporate
“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
28 | MODERN CASTING February 2015
metalcasting facilities early in the design process. There’s a high level of collaboration,” said Jim Stew- ard, Christie’s commodity man- ager. “Identifying and eliminating problems early in the process can help streamline progress and control costs by limiting design iterations.” Te second challenge is inherent in the supplier-customer relation- ship, with the two engineering teams having to marry different consider- ations in a part’s final design.
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