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Old 04-02-2010, 09:38 PM   #3
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Member#: 101117
Join Date: Nov 2005
Chapter/Region: NESIC
Location: Dorchester MA / Sunapee NH
2009 WRX, 06 OBW 3.0
Tiger 1050, WR250R, TW200


Originally Posted by PHATsuby View Post
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!

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.

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.
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Garandman is offline   Reply With Quote