3D Scanning of Patterns and Core Box for ensuring 'the first casting' is complying to nominal values geometrically. Such geometry verification is essential given the complex model of the casting involved with several cores and stringent casting weight, dimensions and costs.
Though CNC technology enhances the quality gaps betweeen the CAD and actual tooling of the pattern or coreboxes, it is still possible that the supplier quality of the pattern design/core box design and subsequent manufacturing can have errors. Any trial of such tooling will result in rework/rejection and fatigue to the team of the foundry and also the customers. Some times, foundries do not get more than one chance to prove their time worthiness for delivering quality castings.
Our team substantially reduces the foundry's problems by enhancing quality and time-to-invoice by co-working with the foundry. Our expertise and experience is valuable to resolve the possible failures within the costs of affordable services.
First Component Inspection/Verification - Typically, first component out of trial is considered as the proof of tooling (pattern/core-box) passing the geometrical test for further evaluating casting for machining. Subsequent testing involves soundness of the casting, machining allowances, assembly tolerances, etc.
Our first component checking will make the pattern makers job easy by proving the foundry-men that the patterns and core-boxes pass the geometry tests. Next phase of qualification for reliable castings will depend on the methoding adapted by the foundry. Experienced foundry-men understand that the deviations caused due to the casting can be inferenced to the cause of the same. Therefore, responsive checks can be implemented to get the immediate castings approved thereby eliminating quality problems and increasing the customers satisfaction.
If you can measure before failure, you can control and prevent errors, easily and quickly.
Pattern Tooling and Methoding - Patterns are checked at the pattern maker end before sending to the foundry for sampling and production certification. However, often due to time and costs optimisation there are areas where the pattern making is often compromised for customer pressure or data not available to them. These compromises results of rejection at the foundry while pouring the first sample. To avoid such pitfalls, it is important that these tooling are verified before taken into production sampling.
Often foundries admit that the process limitations will cause deviations of the dimensions resulting from melting and subsequent cycles. Many times, these errors may originate from the patterns and core-boxes unless checked thoroughly in the first place. This type dimensional checking prevents costly trials and fatigue of the customer for enabling the acceptance of castings from the foundry. Also, it enhances the foundry ability to deliver quickly to the customers without the need for reworks and rejection of the castings.