The use of printed sand mould technology has enabled Maycast-Nokes Precision Engineering Ltd, a UK foundry, to produce ‘ready to use’ prototype parts in weeks, instead of months, providing a cost-effective cast solution for the renewable energy sector.
Component
- A set of wind turbine hubs and servo housings
- Weight: 93kg; Dimensions: 1450mm x 1450mm x 450mm
Alloy
- Aluminium A356-T6
Customer Requirements
- Short lead time of four weeks
Outcome
A reduced lead time of just four weeks, reduced number of pieces to create the mould and more flexibility for the customer to adjust design during development stage as there is no need to scrap expensive patterns. The foundry can offer a one-stop-shop for fully-finished, production line ready castings in large sizes.
Challenges
- Large castings to be produced quickly
- Possible design alterations
Method
- Close working relationship with respected 3D printing company to utilise printed sand mould process.
- Worked with appropriate CAD design from customer.
- The 1450mm x 1450mm x 450mm sand mould packs were printed on a high performance printer with a build space of 4m x 2m x 1m.
- The mould was then produced in only seven individual pieces made up of a top, bottom and five identical cores.
- The material used was GS-14 sand with a layer thickness of 300um.
- The hub was cast in aluminium A356-T6.
- The final casting weighed 93kg, with a cast weight of 150kg, produced in a four-week lead time.
