15th World Conference on Investment Casting WINNERS
Castem Co., Ltd. Wins International Casting Recognition for Cosplay Fictional Axe
The customer approached Castem with the objective of perfectly duplicating a faux axe used in cosplay in aluminum alloy, while maintaining the aesthetic appearance of the item. The original item was hand fabricated from Styrofoam and plastic, without any drawings or 3D models. At the beginning of this decorative axe project, the non- metallic master was 3D scanned and reverse engineered. Patterns were manufactured via the additive manufacturing 3D printing process. The patterns were set up on molds and conventionally cast, finished, pained and assembled. As part of the finished product, the customer received not
only the cosplay axe with moving features as the final product but also 3D models of the parts.
Producing the decorative
axe using reverse engineering and additive manufacturing methods saved the customer an estimated $100,000 in tooling costs as the project would require 40 pieces of tooling. The “fictional” aspect of this project is that in cosplay, the axe head, which stands seven-and-one-half feet tall when staved, is an imaginary weapon that rises to 7,000˚C (12,632˚F) by turning the wheel and it allows you to easily cut through anything like butter.
Castem Co., Ltd.
PART: Fictional Axe Size: 2.3 m, 31 kg Alloy: JIS AC4C (A356)
Turbo Cast (India) Pvt. Ltd. Uses Investment Casting to Meet Nuclear Component Requirements The customer was unsuccessful at obtaining a sand casting
that would meet their requirements for a robotic component used in a nuclear application. The component, a Casting for Shoulder Housing, is made from Aluminum LM 25 alloy and measures 12 in. x 11 in. x 15 in. After five years of effort and repeated attempts, the customer contacted Turbo Cast to assess the feasibility of part development and manufacture using the Investment Casting Process. Not only was Turbo Cast able to satisfy the customer’s
product reliability and performance requirements, but in undertaking the project, Turbo Cast was able to reduce machining cost by achieving complicated geometries in the net casting, thus replacing several assembled components.
PART: Casting for Shoulder Housing Master Size: 12 x 11 x 15” Alloy: LM 25
14 ❘ August 2022 ® Turbo Cast (India) Pvt. Ltd.
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