Giga Casting and What Can it Do


giga casting manufacturing large pieces
heavy duty workbench with anti-vibration levelers

No matter your necessities, Formaspace can construct the precise industrial furnishings on your precise wants. Shown above is a heavy-duty workbench with anti-vibration levelers, mounted with a 2.5” black onyx epoxy high for terribly lengthy life.

manufacturing integrated work station with multiple chutes

Improving the effectivity of your materials dealing with operations could have a constructive impression in your backside line. The customized workstation above options a number of chutes permitting the operator to course of, assemble, or pack objects rapidly.

Find out how the “Giga Press” and “Giga Casting” can change 1000’s of producing processes with single large castings.

Creative engineers and designers can create breakthrough structural designs so revolutionary that they make all the pieces that got here earlier than appear out of date.”

— Formaspace

AUSTIN, TEXAS, UNITED STATES, September 22, 2022 / — Value Engineering Versus Breakthrough Engineering

Structural engineers and product designers are continually in search of methods to make their designs stronger whereas decreasing weight and materials prices, a course of referred to as worth engineering.

Often the success of those adjustments is measured in ounces of misplaced weight or cents on the greenback in price financial savings.

But occasionally, inventive engineers and designers can create breakthrough structural designs so revolutionary that they make all the pieces that got here earlier than appear out of date.

Here are a few examples as an example our level.

In structure, the American development business was remodeled by the introduction of balloon body homes within the early 1800s, the quick, stick-built development technique that changed earlier heavy submit and beam designs. Then, in 1885, the primary skyscraper appeared, Chicago’s 10-story tall Home Insurance Building, which pioneered using a structural metal body development, permitting architects to design our first fashionable multi-story buildings. In 1951 Mies van der Rohe moved this metal construction inward – away from the outside partitions – to create higher views and extra usable area in his design for Chicago’s Lake Shore Drive Apartments, the prototype of right now’s fashionable glass workplace towers.

Vehicle design has additionally seen a sequence of structural engineering breakthroughs. Throughout the Twenties and nicely into the Nineteen Thirties, most quantity automobile manufacturing was “body on frame” – our bodies had been constructed of stamped sheet metallic nailed to picket helps, then later mounted onto a powerful metallic body containing the engine and operating gear. This method was primarily an incremental replace to the longstanding development practices relationship again to the horse-driven carriage period.

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But there was one other method. Budd Manufacturing Company, later well-known for its streamlined railroad vehicles, such because the Pioneer Zephyr, sought to alter issues. In the early Nineteen Thirties, they licensed their revolutionary all-metal unibody car designs (referred to as a monocoque in French) to the French automobile maker Citroën (to be used within the beloved Traction Avant) and Chrysler (for his or her artwork deco-styled Airflow sedan sequence). Budd’s unibody design coalesced your entire car construction into a brilliant robust physique shell, eliminating the necessity for wooden panel helps and a separate body.

While “body on frame” constructions stay in use to at the present time (primarily for vans and heavy SUVs), the vast majority of right now’s fashionable autos use a unibody construction, due to its comparatively decrease weight, larger power, elevated torsional rigidity, diminished vibration, and (often) decrease price.

Introducing Sandy Munro, YouTube’s Breakout Star Advocating For Better Design For Manufacturing

When speaking about manufacturing optimization, we’ve typically introduced up the title of Sandy Munro, founding father of the eponymous Munro Associates, a Michigan-based consulting firm well-known for its no-nonsense automotive teardowns and manufacturing/materials costing evaluation.

It’s exhausting to tug the wool over Munro’s eyes. He’s seen it all throughout his decades-long profession that began as an automotive toolmaker, to cost-analysis challenge supervisor at Ford, to his present fame as an oft-quoted YouTube channel sensation the place he has a cultivated devoted following his extremely detailed movies evaluating engineering design decisions and manufacturing strategies.

Munro is an outspoken advocate of tried-and-true ideas of producing design optimization, together with:

– Promoting the observe of “top-down” development, wherein parts are assembled from the underside layer upwards (with out the necessity to flip or flip the in-process work the wrong way up). This not solely quickens meeting and will increase high quality, it typically makes product restore and upkeep simpler as nicely.

– Reducing or ideally eliminating using fasteners to extend high quality and cut back manufacturing and guarantee prices. (Munro says {that a} research at Ford confirmed that fasteners are a root reason for a majority of guarantee failures – “If you want poor quality, add more screws.”). Useful approaches for attaining this embrace utilizing half designs that may be snapped or glued into place.

– Reduce manufacturing prices by combining a number of half sub-assemblies into one bigger element. For instance, it could also be attainable to interchange an element made up of varied brackets and sheet metallic stampings with a single, bigger molded half – to realize decrease prices and higher high quality.

– Create multi-purpose parts that carry out a number of capabilities, which might cut back prices throughout a number of programs. (Munro factors to the Tesla “Super Bottle” as a first-rate instance; this single water reservoir replaces a number of tanks used within the battery warmth administration and inside heating programs.)

materials dealing with operations customized workstation with chutes

– Improving the effectivity of your materials dealing with operations could have a constructive impression in your backside line. The customized workstation above options a number of chutes permitting the operator to course of, assemble, or pack objects rapidly.

– As an business insider, Munro has direct expertise with how troublesome it could be to create breakthrough engineering applications, just like the Tesla Super Bottle.

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In an interview on Autoline Network, Munro went on considered one of his well-known ‘rants’ about what stands in the way in which of producing innovation at huge established firms:

“This bottle is called the Super Bottle; this bottle does all the cooling – for everything! You’ve got a heat exchanger here for your AC system, a heat exchanger here for the battery module – everything goes through this little bottle here. We were really thrilled with this.

You were asking before, ‘why don’t we see the guys in Detroit do things (like this)?’

Do you know how many different fiefdoms you have to have (onboard) in order to make this happen?

The engine cooling guys (say) ‘uh uh no no, I will not – those are my hoses, this my hose, you can’t have that, this space is mine.’

The arguing and bickering that goes on about cooling is just out of this world. And they (Tesla) took this (which) crosses powertrain, HVAC, and on and on and on, and here they have created something – this isn’t the first time we have ever talked about doing something like this – we’ve talked about it a lot, but because of the Detroit infrastructure – the way that cars are designed you have this ‘you stay out of my territory’ — (which means) you can’t have something like this because it crosses too many lines (of management).”

Case Study: High Cost Of Stamping And Assembling Sheet Metal Panels In Unibody Structures

Let’s flip the dialog again to unibody automobile manufacturing.

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Unibodies have the potential to be cheaper and lighter weight than their ‘body on frame’ brethren.

That mentioned, the traditional manufacturing processes of welding up doubtlessly lots of of particular person sheet metallic stampings to create a whole car physique could be costly – and in a single well-known occasion, deceptively so, as within the case of the well-known authentic Alec Issigonis-designed Mini.

In the early Nineteen Sixties, Ford manufacturing consultants tore down a brand new Mini to attempt to uncover how BMC may promote it for such an astonishingly low value – solely to find that BMC was doubtless shedding round 30 kilos on every Mini bought (equal to about 6% of the gross sales value). Ford was proper, BMC’s hit automobile was shedding them cash on every sale, which later helped drive BMC right into a sequence of undesirable mergers and finally chapter.

Read extra…

Julia Solodovnikova
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