Graphicast LTA Casting Process Described in Detail on New Video

March 4, 2010

We’ve just posted a new video to the Graphicast You Tube channel. You can now see the Graphicast LTA casting process unfold in slow motion, with each step explained in a thrilling narration. Just like in the Olympics, breaking the action down into slow motion with analysis along the way helps you better understand what’s happening during the process and, hopefully, gives you a better appreciation of the finer points of the process.

Everything You Always Wanted to Know About Graphicast, But Were Afraid to Ask

February 11, 2010

With no apologies to Woody Allen for the title, we do get a lot of questions about how our process works. And not just our casting process, but the whole process, from beginning to end. How do we design and  make the molds, how do we program the CNC machines, how does the CMM work, etc. We’ve tried to answer these questions with a virtual Graphicast plant tour, highlighting the process we follow in developing a new part for you. All of this is in a  4 1/2 minute video on the Graphicast channel on You Tube. You can see all your favorite Graphicast characters (and they are characters), including a cameo role by your blogger as a CNC machinist. If a picture is worth a thousand words, the video should be worth millions.  I hope you find it helpful to your understanding of Graphicast, and how we work with you to make your parts.

Unconscious Competence

January 7, 2010

Last night, I attended the Boston Symphony Orchestra open rehearsal. The renowned cellist, Yo Yo Ma, was the soloist.  Watching and listening to him, I couldn’t help but notice his ever present smile, his attentiveness to the orchestra and the conductor, his engagement with the music, his absolute joy in playing the music of Haydn. He wasn’t looking at his fingers, or overtly thinking about how to play the cello. He was displaying unconscious competence. He wasn’t focused on the mechanics of playing. He was focused on communication with the audience and orchestra and interpretation of the composer’s intent.  

I’d like to think that when you work with Graphicast, we are also displaying unconscious competence. We’re not focused on learning how to design and manufacture a part. We do it so well, we can move beyond that  in our awareness. We’re focused on communicating with you and trying to interpret your design intent into a casting that is a masterpiece of craftsmanship and execution. If  we do our best for you and you tell us we are the Yo Yo Ma of casting, we’ll know what you mean.

Graphicast LTA Casting Process on YouTube

December 4, 2009

We now have a computer simulation of our casting process available (see video below or visit the Graphicast YouTube channel). This  9 second video shows how the mold smoothly fills with Graphicast’s LTA casting process and how the temperature of the metal changes with time during the casting cycle.

Casting Design – We Have An App For That

November 30, 2009

When a part design comes in for us to quote, most of the time I receive it to process.  I pull the part file in, log it and review it for manufacturability.  I have done this for a while and I’m rarely surprised at what people are trying to manufacture, but do enjoy seeing the creativity and uniqueness in each design.

More often than not, Graphicast receives part designs to be produced on a CNC machine (if this sounds familiar please look into our DRPS  program).  This scenario can build into the part costly to produce features and design intent.  Once imbedded in the design, these can affect other parts, if not the overall functionality of the unit the part is in.  Far too often, the final manufacturing process is not considered during this early design phase and real problems like space, cost, functionality, and manufacturability become serious issues downstream.  It’s these same problems that caused Albert Einstein to have the hair he had.

Good designs don’t just happen, they are carefully thought out.

Ok, I might not have an “App” for casting design, but I welcome any casting design questions you have.  I would be glad to help, discuss or review any design or manufacturability situations you find yourself in.  Please feel free to contact me directly (sales@graphicast) or respond to this blog so that others can learn from you insight as well.

Please find & follow us on – LinkedIn, Facebook and Twitter

How Does 3D Print Technology Affect Your Business?

November 12, 2009

For some,  3D printing has great interest. There is a fascination in developing a solid 3D component on the screen and then watching it get created in thin air.  For others,  it’s the fact that this “thing” did not exist 2 hours ago and now I have one in my hand.  How cool is that?  Technology has come a long way, so much that 3D printing has become incredibility popular.

For those of you that find this technology interesting or would like to know how it fits into our manufacturing process at Graphicast, please see my comment on the LinkedIn, CNC Machining / Manufacturing Network group.

Design Considerations

September 30, 2009

Casting Design Basics

As with all casting methods, uniform walls work best. Heavy sections must be at
the part perimeter to allow direct gating or must be connected to the perimeter with
heavy feeding ribs.

Milling operations can be eliminated through the use of flat surfaces parallel to
the parting plane. Drilled clearance holes or tap drill sizes are replaced with
cored holes.

The following guidelines should be considered:

• Sizes: Up to 12″ x 14″ x 5″Up to 20″ if narrow
• Radii parallel to parting line: 0.030″ minimumRadii normal to parting line: 0.063″ minimum
• Walls: Must be of uniform thickness from .125″ to .25″.
  Avoid heavy sections.
• Draft: 2° nominal on all surfaces perpendicular to parting plane
  (See Draft Requirements.)
• Gates/Risers: Allow for heavy gates (60% to 80% of prevailing thickness)
  on perimeter of part at parting line.
• Lettering: Raised lettering or artwork can be accommodated.
• Avoid:Applications over 300°F; multiple side pulls (slides)

Tolerances

• General Dimensions: First inch ± .005″; Additional inches ± .002″
• Critical Dimensions: First inch ± .003″;Additional inches ± .001″ per inch
• Across parting line: Add ± .005″ to above
• From side core: Add ± .005″ to above

Draft Requirements

To protect the graphite mold, adequate draft is required on all surfaces
perpendicular to the face (parting plane) of the mold. Normally, 2° of draft per
side is adequate, but thin sections may require 3° to 4°. On part drawings,
plus or minus draft should be specified for all dimensions affected by draft,
not indicated by angled lines.

“Plus” draft indicates that draft increases the size of the feature
described.

“Minus” draft indicates that draft decreases the size of the feature
(see drawing below).

« Previous Page