Case Studies
Winner of Energy Casting Award Saves Time and Significant Savings
“An existing customer utilizes cooling nozzles in their
production process that have a useful life of more than 15 years, making the need for replacement difficult to predict. Lengthy production stoppages are unacceptable, and conventional replacement parts have a lead time of more than 30 weeks. In need of a prompt solution, the customer turned to TPM,” explains Antonio Garcia. Working from an existing component, TPM created a 3D model and produced replacement parts via rapid prototyping of the ceramic core and wax pattern. Due to the high temperatures at which these nozzles operate, HIP, Dye Penetrant and X-Ray were required, and the parts were outsourced to accomplish this. Requiring only seven weeks to produce the components, TPM’s approach saved their customer millions of dollars due to downtime avoidance.
PART: Syngas Cooler Nozzle Size: 49 lbs, 11” in diameter Alloy: WC9
TPM, Inc.
Autonomous Electric Vehicle Radar Bracket Finds its “Eyes” in Investment Casting
“When one of our customer who specializes in automotive
mirror brackets came across this unique application, they knew that we could help them maintain their tight delivery schedule with high quality product,” Paul Leonard explained. During review of the customer’s design, Aristo-Cast engineers suggested changes to enhance the casting’s performance. They utilized their 3D printing resources to produce prototype components for testing during tool build. After heat treatment, machining and coating, the first components were evaluated, where it was discovered that several minor modifications would enhance part functionality while simultaneously reducing assembly time. The changes were incorporated into the solid model file, and new prototypes were produced, tested and verified. The resulting modifications were incorporated into the tool build without impact to schedule. With electric autonomous vehicles being produced
at lower than traditional automotive volumes and with the resulting design maximizing effectiveness while minimizing weight, this component lends itself nicely to the investment casting process.
Aristo-Cast, Inc.
PART: Autonomous Electric Vehicle Radar Bracket Size: 9.482 x 8.765 x 6.015” Alloy: Aluminum
January 2019 ❘ 19 ®
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