Metalcasting Industry Roadmap x Ability to utilize a casting design from the onset of the part development
f. Cost Estimating ± The ability of both the foundry and the customer to estimate cost is necessary to identify good casting candidates and then optimize them. Cost estimating provides the foundry with a basic rough order of magnitude cost to see if a part will be a good fit. Cost estimating provides the customer with a means to assess the supply chain to vet procurement. Simple cost estimating can be based on characteristics of a casting design such as number of cores and isolated heavy sections. It should be noted that even advanced costing packages such as aPriori struggle with the variables associated with castings such as order quantity, type of tooling, method of manufacturing, and supply and demand. Therefore, an estimate would likely better serve as an identification of cost drivers in a given design.
Key Tasks
x Identify cost inputs for castings x Select and prioritize key cost factors to assess cost magnitude x Develop simple tools to analyze cost drivers
Target Outcomes
x Technology to assess casting designs for cost x Mechanism to educate both the foundry and customer on cost drivers
Additive Manufacturing (AM) Technology
a. Design Rules for AM (Cores and Molds) ± AM offers new capabilities for producing cores and molds. Understanding when these can be leveraged, and that printing technology for casting does not result in a printed casting are important for setting the right expectations and not exceeding capabilities. AM offers the ability to print reverse draft or internal features that would be difficult or impossible to do otherwise; thus, offers unique
flexibility and applications. AM tooling can be used to prove runs such as prototype
development. Unfortunately, if casting is not identified in this initial design phase it is often never again considered as the additional cost to design and test the part cannot be overcome. Finally, expanding what industry has already leveraged in applying AM to casting will advance additional capabilities for casting designers.
46 Design
out
manufacturability of a design as traditional casting tooling cost and lead-time can preclude cast parts from consideration for low volume
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