The Casting Design Approach -- The casting design engineers at the Dotson Company of Mankato, MN had three imperatives for an integrated casting design.

• Design for Performance

• Design for Manufacturability/Castability

• Design for Cost

Critical Casting Design Issues --The requirements for performance, manufacturability/ castability, and cost are closely interconnected. Five design issues played a major role in meeting the three design imperatives

• Choose an iron alloy that met the strength, fatigue life, and machining requirements.

• Review the component design to produce the near-net shape and reduce finish machining operations

• Design  the mold system to reduce overall manufacturing costs.

• Develop the riser system   to insure quality and improve yield.

• Select a a pattern material  to minimize tool cost with the large production volume.

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