Difficulty/Cost of Casting Custom Parts?

[PHATsuby]

Hey Everyone,

This is for anyone that has any experience with manufacturing or that has looked into it. I am curious the process and average cost per part on something like an intercooler endtank or an intercooler tube.

If my dreams are ever realized(and depending on costs) I would need a couple things cast and possibly a few things injection molded if possible. This would be on a larger scale but not huge, I'm thinking 20 per part.

I know casting requires a mold, and I should be able to model the part in SolidWorks myself and hopefully create a mold from that. Would it be a matter of modeling the mold then having it CNC'd and then casting? If I take care of the modeling/engineering portion anyone have an estimated cost of the creation of the mold and casting?

Secondly one thing I may have to do is a fairly organic shape not easily made by cutting/shaping tubing. In the attempts to make things as OEM quality as possible and ease of reproduction I am wondering about making resin based parts similar to the intake manifolds on the Legacy GT's and newer WRX's. Again I can likely model this in SolidWorks myself but I am not familiar with how complicated it is to get this created.

Any thoughts on cost and process related would be much appreciated. Yes I have the ability to custom fabricate as well and my intent on doing this is to hopefully make the parts very consistent and high quality.

Thanks for the help!

Ben

* Registered users of the site do not see these ads.

[Token-Negro]

Id contact AMS they cast quite a few parts.

[Garandman]

Originally Posted by PHATsuby

Hey Everyone,

This is for anyone that has any experience with manufacturing or that has looked into it. I am curious the process and average cost per part on something like an intercooler endtank or an intercooler tube.

If my dreams are ever realized(and depending on costs) I would need a couple things cast and possibly a few things injection molded if possible. This would be on a larger scale but not huge, I'm thinking 20 per part.

I know casting requires a mold, and I should be able to model the part in SolidWorks myself and hopefully create a mold from that. Would it be a matter of modeling the mold then having it CNC'd and then casting? If I take care of the modeling/engineering portion anyone have an estimated cost of the creation of the mold and casting?

Secondly one thing I may have to do is a fairly organic shape not easily made by cutting/shaping tubing. In the attempts to make things as OEM quality as possible and ease of reproduction I am wondering about making resin based parts similar to the intake manifolds on the Legacy GT's and newer WRX's. Again I can likely model this in SolidWorks myself but I am not familiar with how complicated it is to get this created.

Any thoughts on cost and process related would be much appreciated. Yes I have the ability to custom fabricate as well and my intent on doing this is to hopefully make the parts very consistent and high quality.

Thanks for the help!

Ben

Stratasys makes a Fortus rapid prototyping machine that can make parts out of PPSF. It is used by Ford, Ducati and others to dyno test prototype exhaust manifolds, so it is tough stuff. They have white papers on making casting patterns. http://www.fortus.com/

One part might only cost you $500 to $1,000, far cheaper than trying to amortize a mold which could be hundreds of thousands.

Castings vary depending on material and shape but you need patterns, machining after casting, must specify the alloys, etc etc.

If you have a BSME you probably learned all you need, you just have to remember it.

[PHATsuby]

Originally Posted by Token-Negro

Id contact AMS they cast quite a few parts.

Haha funny you say that because that is exactly what I thought as well.

Garandman, thanks for the info! I started out in ME but didn't finish so I am only an amateur. That is great info though, I appreciate it.

Ben

[coxy]

A friend and I had 50 Twin Weber manifolds made 20 years ago,back then it cost us $250.00 for the wooden patterns and the Foundry charged out at $50.00 for 1~10 units ,$35.00 for 50 units and if we wanted a run of 200 it would drop to $22.50 each.
We did all the finish machining ourselves.
Quality manifolds back then sold for $180.00 to $250.00 each.
People forget there are options other than CADCAE or CNC as it is more commonly called.

[Garandman]

Originally Posted by coxy

A friend and I had 50 Twin Weber manifolds made 20 years ago,back then it cost us $250.00 for the wooden patterns and the Foundry charged out at $50.00 for 1~10 units ,$35.00 for 50 units and if we wanted a run of 200 it would drop to $22.50 each.
We did all the finish machining ourselves.
Quality manifolds back then sold for $180.00 to $250.00 each.
People forget there are options other than CADCAE or CNC as it is more commonly called.

CAD = Computer-Aided Design
CAE = Computer-Aided Analysis - not discussed here.

CNC = Computer Numerical Control [machining] which is done with CAM software to generate the machine instructions.

Try and find a pattern maker today to make you a manifold pattern for $250.

In the meantime, if you have the CAD file we can make a plastic pattern overnight in a DDM machine.

[PHATsuby]

Garandman, PM'd you.

If anyone else has other info as well that would be great.

Thanks!

Ben

[CC4nj]

Look up companys that sell/and have support for CAD/CAM systems like MasterCAM...most of these places have rapid prototype machines.
If you have a part drawing or even just a rough sketch someone should be able to help you.
Once you have a prototype and can actually fit it and make any changes then seek out a casting place.

[Garandman]

Originally Posted by CC4nj

Look up companys that sell/and have support for CAD/CAM systems like MasterCAM...most of these places have rapid prototype machines.
If you have a part drawing or even just a rough sketch someone should be able to help you.
Once you have a prototype and can actually fit it and make any changes then seek out a casting place.

Yeah, we have 12 of them.....

A rough sketch or drawing doesn't help anyone: a 3D CAD file will help everyone.

In Solidworks select File - Save-As and selecte .STL. That is the format used by RP machines.