Case Studies

TRUSTED SPEED & PERFORMANCE

Challenge

Sulzer Pumps needed a complex 300 lb casting, developed from concept to completion in 4 weeks.

Solution

To produce a large, complex investment casting quickly, Tech Cast used additive manufacturing technology to expedite this critical casting. This solution saved time and money while producing a part with extraordinary dimensional accuracy.

Results

“Tech Cast’s execution of our highly critical order was beyond expectations. With a customer in dire need, their team rose to the occasion to meet our aggressive schedule without compromising quality. We appreciate the support provided by Tech Cast and will not hesitate to work with them in the future”
-Monica Sawatzky, Senior Buyer, Sulzer Pumps (Canada) Inc.

Why risk production downtime?
Specify the proven performance leader: Tech Cast.

Complex Castings from Tech Cast

Bearing Housing Produced Without Tooling from 3D Printed Ceramic Core & Pattern

Problem & Tech Cast Solution

Why did you choose an investment casting over other options?
The internal water passage required the use of chaplets, which we wanted to avoid. Investment casting and a printed core would solve this issue. SLA printed patterns were selected to save money on permanent tooling for this low volume production run. Eagle Engineered Solutions provided their “mold ready” Direct Print Ceramic (DPC) Cored Pattern coupled with SLA QuickCast™ pattern material with integrated gating.

What problems did the investment casting solve?
Dimensionally the investment castings and their internal/external surface finishes were superior to sand cast tolerances.

Were there any cost savings (i.e., tooling)?
Yes, the SLA patterns negated the need for permanent tooling, saving both time and money.

“We selected Tech Cast because of the time sensitive and complex nature of our project. Utilizing their experience with SLA printed pattern tooling saved us time and money, with the added bonus of achieving dimensional accuracy and surface finish surpassing that of typical sand castings traditionally used for this type of product.”

SLA Parts from Tech Cast

Better Surface Finish. Faster Delivery. No Tooling.

Challenge

Surface finish and casting integrity were not as desired (from another foundry) and tooling was not available.

Tech Cast Rapid Casting Solution

Our recommendation was to convert the part to an investment casting using SLA, a form of 3D printing technology.

Results

  • Better Surface Finish
  • Increased Casting Integrity
  • No Tooling Needed
  • Quicker Delivery
“We chose to make this as an investment casting for the superb surface finish and increased casting integrity. Our customers are demanding the highest quality and when we have the opportunity to convert a part to an investment casting, we do so. Tech Cast produced this as an SLA part which was an excellent option for us, as we were able to have these in a fraction of the time it would have taken to develop new hard tooling.”
-Randy Johnson
Flowserve Purchasing Supervisor

Impeller Cast Using SLA-Printed Patterns

Needing to replace two double suction impellers with 30-in. diameters, SPX, Charlotte, North Carolina, decided to explore alternative casting processes to improve performance and limit lead times. It contacted Tech Cast LLC, Myerstown, Pa., a producer of large (up to 500 lbs.), precision engineered investment castings using stereolithographic (SLA) rapid prototype technology, an additive manufacturing process that produces objects from CAD models by printing successive layers of curable resin that are hardened via ultraviolet light.

New Single-piece Investment Casting Replaces 7-part Fabrication

When you can combine a seven-piece fabrication into a single casting and have a new component which is stronger, more dimensionally consistent, and more attractive yet at lower cost, the decision is a no brainer.

That was exactly the situation for Tait Towers, a leader in the design and quality staging for the touring entertainment industry as it commissioned Tech Cast, Inc. of Myerstown PA to cast a part for their staging equipment.

Casting No Doubt

Designing a pump impeller that performs well is challenging. The fluids being pumped are often multi-component, and the flow velocities and volumes are high, which make predicting performance analytically very difficult. Performance is best optimized experimentally using an iterative process: design an impeller, cast the design, test the performance, make a design change, cast the new design, and retest, and so on until an optimum design is reached.

Fork Roller Case Study

Tech Cast Inc. (www.techcastinc.com), Myerstown, PA, managed to “design out” some of the heavier features of this fork roller used in a metal forging operations, which measures 18×16×20 in. The near net shape made it possible to reduce machining, resulting in a component that is lighter than the 260 lb forging it replaces (and which began as a 740-lb block of 15-5 pH stainless steel. It also costs 39% less per finished piece.

Republished with permission from Penton Media Inc.

500 lb Impeller Case Study

Tech Cast, LLC, a leader in the production of large, precision-engineered investment castings using SLA Rapid Prototype technology, recently engineered a 500 lb closed impeller casting - in less than six weeks from receipt of CAD file - with reduced tooling costs and more!

INVESTMENT CASTING

Parts with complex geometries and intricate details can be created with this process.

RAPID PROTOTYPING

For R&D, part repairs, reverse engineers, low production quantities. Tech Cast can meet all of your SLA Rapid Prototype requirements.

Case Studies

Learn about how Tech Cast’s full range of capabilities can deliver the product that best meets your needs.

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