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A Design Study in Rapid Prototyping for Castings                                        
Lessons Learned
Prototype Casting and InFocus engineers worked closely together on engineering this prototype casting.

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Machined Casting

The successful production of the prototype illustrates that --
  • Magnesium was the material of choice for weight and stiffness, understanding that magnesium casting requires careful process control

  • Careful casting design of the thin walls and flow patterns is necessary to produce smooth metal flow and minimize transitions, which produced castings without microcracking or cold tears.

  • Optimized engineering used a single core  mold design in this complex piece, reducing die complexity and cost.


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Copyright 2002 by the American Foundry Society  All rights reserved. 
Address comments to:  jss@afsinc.org
Last Modified:September, 2002 by STG

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In cooperation with
prototype
casting, Inc

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