Feature Article
Castem's Digital Cast Service Solves Extensively Machined Parts Assembly
Background T
he high-performance motorcycle industry thrives on precision, efficiency, and innovation. For
Yoshimura, a leading supplier of custom motocross and dirt bike parts to OEM manufacturers, these principles are non- negotiable. When faced with challenges in producing a manifold flange for an exhaust system, Yoshimura turned to Castem Co., Ltd., a globally recognized precision casting company based in Fukuyama City, Hiroshima, Japan. A member of the Investment Casting Institute (ICI) since 2015, Castem specializes
in Investment Casting
and Metal Injection Molding, with innovative approaches to prototyping for both services. Their Digital Cast service, a blend of additive manufacturing and investment casting, offered Yoshimura a solution to address
bottlenecks, streamline design validation, and cut manufacturing costs.
20 ❘ February 2025 ®
The Problems: Design Challenges and Manufacturing Bottlenecks Initially, the flange section and the oval- shaped piece that together make up the manifold were produced separately: the flange was laser-cut and then extensively machined, and the inner oval-shaped component was fully machined- an average machining cycle time of over 30 minutes per part. Once the individual parts were
production
machined, the assembly process then introduced potential inconsistencies and additional complexity. Unsurprisingly, these lengthy machining and assembly times caused extreme production bottlenecks. However, any changes to the component design that might alleviate these manufacturing challenges required validation by the OEM - adding pressure to an already tight timeline. The extended machining cycles and multiple production phases also drove up costs,
making the process even more time- consuming and expensive.
The Solution: Digital Cast Castem’s Digital Cast service combines the precision of 3D printing technology with the efficiency of traditional investment casting. One of the first steps was transitioning the material from 303 stainless steel to 304 stainless steel. This change offered superior corrosion resistance and was better suited for the casting process. Castem then optimized the design of the manifold flange by reimagining it as a single cast component, eliminating the need for assembly and significantly reducing machining requirements. Castem was then able to quickly produce precise 3D printed molds, ensuring that prototypes were delivered within the stringent two-week deadline required for the validation process. This integration of advanced technology
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