Aluminum Casting Design & Engineering
Design Support Before the First Casting Is Poured
A successful aluminum casting starts long before metal enters the mold. At Cast Metals Technology, we work with customers during the design and development process to help create cast components that can be manufactured consistently, efficiently and to the required specifications.
Whether you are developing a new component, converting a fabricated or machined part to a casting, or transferring existing tooling from another foundry, CMT can provide practical engineering support based on real-world aluminum sand casting experience.
Design for Manufacturability
Casting design decisions can have a significant impact on quality, tooling, machining requirements and overall production cost. Our team reviews customer drawings and 3D models with the manufacturing process in mind.
Depending on the application, our engineering review may consider:
The objective is straightforward: identify potential manufacturing challenges early, before they become production problems.
Wall thickness and transitions
Draft requirements
Parting line location
Core requirements and core design
Gating and risering
Shrinkage considerations
Machining stock and machining requirements
Critical dimensions and tolerances
Tooling design and manufacturability
Potential areas for porosity or shrink-related defects
From Concept to Production
CMT works with customers at multiple stages of the product lifecycle. We can assist with new casting designs as well as established components that need to be improved, retooled or transferred.
New Product Development
Review of new component designs to help determine whether they are well suited for aluminum sand casting.
Casting Redesign
Evaluation of existing cast components when dimensional, quality, cost or production issues create a need for improvement.
Weldment or Fabrication Conversion
Evaluation of fabricated assemblies that may benefit from being redesigned as a single aluminum casting.
Transferred Tooling
Engineering review of existing patterns, core boxes and casting designs when production is being transferred to CMT from another foundry.
Casting and Machining Integration
When CMT is providing machining in addition to the casting, we can evaluate the component with both processes in mind.
Engineering Supported by Casting Simulation
For appropriate applications, CMT can use casting simulation and solidification analysis to evaluate how a proposed casting and gating system are expected to fill and solidify.
Simulation gives our engineering team another tool for identifying potential problem areas and evaluating design changes before committing to production.
Learn more about our Casting Simulation & Solidification Analysis capabilities.
Engineering Experience That Continues Into Production
The advantage of working with CMT is that engineering is connected directly to the foundry and manufacturing process. Designs are evaluated with an understanding of how patterns are built, molds are produced, cores are assembled, aluminum is poured, castings are finished and components are machined.
That practical manufacturing perspective helps bridge the gap between a CAD model and a repeatable production casting.
Frequently Asked Questions
Can CMT review my casting design before tooling is built?
Yes. Early design review can help identify potential manufacturability, tooling, core and machining considerations before production tooling is finalized.
Can CMT help convert a machined or fabricated part into a casting?
CMT can review components to determine whether an aluminum casting may be a practical manufacturing alternative.
Can CMT review tooling being transferred from another foundry?
Yes. CMT can evaluate transferred tooling and the associated casting design as part of the transition process.
Have an Aluminum Casting Project?
Send CMT your drawing, CAD model or existing casting information. Our team can review the application and discuss potential design, tooling, casting and machining considerations.