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Looking for Sand Casting company - any recommendation? #1604436 04/07/14 06:02 PM 04/07/14 06:02 PM
Joined: Aug 2007 Posts: 294 Phoenix, AZ M MCTPhoenix OP enthusiast
MCTPhoenix OP enthusiast M Joined: Aug 2007 Posts: 294 Phoenix, AZ	Has anyone here had any experience with hiring a company who can make sand castings? I'm contemplating a reproduction project.. I need aluminum parts made. A large company told me their mold / tooling could run 30-50k which is out of the question. He said someone who does sand-casting would be much better suited to a smaller project. He said he'd try to get me a referral. I figured I'd look to the forum for suggestions / recommendations. Thanks everyone!

Re: Looking for Sand Casting company - any recommendation? [Re: MCTPhoenix] #1604437 04/07/14 08:33 PM 04/07/14 08:33 PM
Joined: Jan 2003 Posts: 15,754 Jefferson State S srt ESYC
srt ESYC S Joined: Jan 2003 Posts: 15,754 Jefferson State	terminal brass and aluminum foundry in south san francisco. I think he can still get patterns made as well. I first found used them in the early 80's for small one-off pieces, they didn't like making patterns then, but I had a guy. I think they now have one working in house, I could check, but I suggest you give Wayne a call and talk with him.

Re: Looking for Sand Casting company - any recommendation? [Re: srt] #1604438 04/07/14 09:50 PM 04/07/14 09:50 PM
Joined: Jan 2003 Posts: 4,323 NY NY 3 340duster340 master
340duster340 master 3 Joined: Jan 2003 Posts: 4,323 NY NY	find a good product development firm, have them 3d scan it, or render the part by hand, take the CAD file and shop bids from MFG.com (globally)

Re: Looking for Sand Casting company - any recommendation? [Re: srt] #1604439 04/07/14 10:18 PM 04/07/14 10:18 PM
Joined: Aug 2007 Posts: 294 Phoenix, AZ M MCTPhoenix OP enthusiast
MCTPhoenix OP enthusiast M Joined: Aug 2007 Posts: 294 Phoenix, AZ	Quote: terminal brass and aluminum foundry in south san francisco. I think he can still get patterns made as well. I first found used them in the early 80's for small one-off pieces, they didn't like making patterns then, but I had a guy. I think they now have one working in house, I could check, but I suggest you give Wayne a call and talk with him. By making patterns do you mean making a mold from scratch (design) or them using my part to create a mold to make more parts?

Re: Looking for Sand Casting company - any recommendation? [Re: 340duster340] #1604440 04/07/14 10:21 PM 04/07/14 10:21 PM
Joined: Aug 2007 Posts: 294 Phoenix, AZ M MCTPhoenix OP enthusiast
MCTPhoenix OP enthusiast M Joined: Aug 2007 Posts: 294 Phoenix, AZ	Quote: find a good product development firm, have them 3d scan it, or render the part by hand, take the CAD file and shop bids from MFG.com (globally) I know so little about this. So do I google 3D scan or something and hire a company to do that? I thought that leads to the expensive $30-$50K type of mold I'm not looking for?

Re: Looking for Sand Casting company - any recommendation? [Re: MCTPhoenix] #1604441 04/07/14 10:58 PM 04/07/14 10:58 PM
Joined: Jan 2003 Posts: 4,323 NY NY 3 340duster340 master
340duster340 master 3 Joined: Jan 2003 Posts: 4,323 NY NY	i used to do the 3D rendering, i never had experience with 3d scanning, but what either will give you is a 3D drawing of your part that manufacturers can uses to figure out how they will make your part. you need to specify material and process but the CAD file format can be interpreted by them to have all the dimensions, etc. i am not familiar with pricing for this type of service, but here is a company that came up on the google search...prices seem reasonable ( a few hundred). http://www.3dscanservices.com/samples2.aspx once you have the cad file, you can shop it for quote on manufacture, or better yet ask the scanner guys what to do, they are definitely more up-to-date than i am! you might need to pay more if you need them to clean up the image, but still seems cheap

Re: Looking for Sand Casting company - any recommendation? [Re: MCTPhoenix] #1604442 04/07/14 11:14 PM 04/07/14 11:14 PM
Joined: Jan 2003 Posts: 15,754 Jefferson State S srt ESYC
srt ESYC S Joined: Jan 2003 Posts: 15,754 Jefferson State	the patterns are the sand that the part is cast into. you supply the model of what you want cast, the pattern makers create a sand mold and the foundry casts the raw part that you finish/machine. Call them they have been doing small runs, even single items for as long as I've known (unless something recently changed).

Re: Looking for Sand Casting company - any recommendation? [Re: srt] #1604443 04/08/14 07:55 AM 04/08/14 07:55 AM
Joined: Jul 2008 Posts: 75 Lakeland, FL S sixpakchallenger member
sixpakchallenger member S Joined: Jul 2008 Posts: 75 Lakeland, FL	The first thing you need is a CAD model of the part you want to make. After you have the model you can talk to a sand casting house. Depending on the number of parts, you can either have the parts run "loose", or have a match plate made. Running loose limits you to about 10 parts. Match plate will give you hundreds of parts. Review these pages: http://www.foundry.ray-vin.com/matchplate/matchplate.htm http://thelibraryofmanufacturing.com/metalcasting_sand.html I could be more helpful if I knew what part you want to make and the alloy. I deal with low volume sand castings daily and I typically 3D print the master and supply to the casting house, or print the splits to be made into the match plate. We use 356-T6 2007 Mustang GT Vert 2004 Ram 2500 QC 4X4 1971 Challenger Vert 5.7 Hemi Project

Re: Looking for Sand Casting company - any recommendation? [Re: sixpakchallenger] #1604444 04/08/14 02:32 PM 04/08/14 02:32 PM
Joined: Aug 2007 Posts: 294 Phoenix, AZ M MCTPhoenix OP enthusiast
MCTPhoenix OP enthusiast M Joined: Aug 2007 Posts: 294 Phoenix, AZ	[quote I deal with low volume sand castings daily and I typically 3D print the master and supply to the casting house, or print the splits to be made into the match plate. We use 356-T6 I have an original 15" Recall Wheel that I want to remove the center to use to make a mold. Once centers are recast it shouldn't be difficult to assemble them into new wheel shells.

Re: Looking for Sand Casting company - any recommendation? [Re: MCTPhoenix] #1604445 04/08/14 04:08 PM 04/08/14 04:08 PM
Joined: Oct 2005 Posts: 8,872 Ontario, Canada S Stanton Don't question me!
Stanton Don't question me! S Joined: Oct 2005 Posts: 8,872 Ontario, Canada	??? Aren't the recall wheels already being reproduced? Seems to me you'd be reinventing the wheel - no pun intended! Since you're dealing with aluminum you can't just make a mold from the original as you have to account for the shrinkage of aluminum - which is significant. The ideal way in this day and age of modern technology would be to determine the shrink factor and have someone do a cad program of the desired item taking that shrink factor into account. Then have the item made on a 3D printer and then use that to make the mold. See shrink factors here: http://www.shelmetcastings.com/shrinkage-allowance-for-metal-casting.html Since these guys also claim to be "short run experts" they me be who you want to talk to. I have no idea - I just googled "shrink factor" and they popped up!

Re: Looking for Sand Casting company - any recommendation? [Re: MCTPhoenix] #1604446 04/08/14 04:35 PM 04/08/14 04:35 PM
Joined: Jan 2003 Posts: 104,346 Garden Grove, CA OzHemi Penguin-hating Ginger
OzHemi Penguin-hating Ginger Joined: Jan 2003 Posts: 104,346 Garden Grove, CA	https://board.moparts.org/ubbthreads/show...e=1#Post8101496 Getting a mold made for cast wheels is no big deal...

Re: Looking for Sand Casting company - any recommendation? [Re: Stanton] #1604447 04/08/14 06:01 PM 04/08/14 06:01 PM
Joined: Jan 2007 Posts: 10,133 A Red State SNK-EYZ I Live Here
SNK-EYZ I Live Here Joined: Jan 2007 Posts: 10,133 A Red State	Quote: ??? Aren't the recall wheels already being reproduced? Seems to me you'd be reinventing the wheel - no pun intended! Since you're dealing with aluminum you can't just make a mold from the original as you have to account for the shrinkage of aluminum - which is significant. The ideal way in this day and age of modern technology would be to determine the shrink factor and have someone do a cad program of the desired item taking that shrink factor into account. Then have the item made on a 3D printer and then use that to make the mold. See shrink factors here: http://www.shelmetcastings.com/shrinkage-allowance-for-metal-casting.html Since these guys also claim to be "short run experts" they me be who you want to talk to. I have no idea - I just googled "shrink factor" and they popped up! A buddy of mine is wanting a set of recall wheels and so far he can't find a vendor that has any. From what he's been told they may not reproduce any more of them. Kayse can't keep up at all now. lol

Re: Looking for Sand Casting company - any recommendation? [Re: sixpakchallenger] #1604448 04/08/14 06:18 PM 04/08/14 06:18 PM
Joined: Jul 2008 Posts: 75 Lakeland, FL S sixpakchallenger member
sixpakchallenger member S Joined: Jul 2008 Posts: 75 Lakeland, FL	Good website to use to estimate tooling and part cost http://www.custompartnet.com/ Estimators for injection molding, diecasting, sandcasting and Machining 2007 Mustang GT Vert 2004 Ram 2500 QC 4X4 1971 Challenger Vert 5.7 Hemi Project

Re: Looking for Sand Casting company - any recommendation? [Re: sixpakchallenger] #1604449 04/08/14 09:38 PM 04/08/14 09:38 PM
Joined: Jan 2003 Posts: 16,376 D dogdays I Live Here
dogdays I Live Here D Joined: Jan 2003 Posts: 16,376	In my mind, better than casting would be digitizing the part and then reproducing it with a CNC machine from billet. It's going to cost hundreds per wheel any way you slice it. R.

Re: Looking for Sand Casting company - any recommendation? [Re: dogdays] #1604450 04/09/14 01:13 AM 04/09/14 01:13 AM
Joined: Oct 2005 Posts: 8,872 Ontario, Canada S Stanton Don't question me!
Stanton Don't question me! S Joined: Oct 2005 Posts: 8,872 Ontario, Canada	But you can't reproduce the cast finish with billet. No doubt billet would be the way to go if it were an option.

Re: Looking for Sand Casting company - any recommendation? [Re: Stanton] #1604451 04/09/14 02:10 AM 04/09/14 02:10 AM
Joined: Nov 2005 Posts: 237 USA G Grizzly69 enthusiast
Grizzly69 enthusiast G Joined: Nov 2005 Posts: 237 USA	Quote: But you can't reproduce the cast finish with billet. No doubt billet would be the way to go if it were an option. The "cast" finish on the recall wheels is... Paint.

Re: Looking for Sand Casting company - any recommendation? [Re: SNK-EYZ] #1604452 04/09/14 02:15 AM 04/09/14 02:15 AM
Joined: Nov 2005 Posts: 237 USA G Grizzly69 enthusiast
Grizzly69 enthusiast G Joined: Nov 2005 Posts: 237 USA	"A buddy of mine is wanting a set of recall wheels and so far he can't find a vendor that has any. From what he's been told they may not reproduce any more of them." http://www.specialtywheel.com/product-showcase/mopar/mopar-warrior-wheel.html

Re: Looking for Sand Casting company - any recommendation? [Re: Grizzly69] #1604453 04/09/14 02:51 AM 04/09/14 02:51 AM
Joined: Jan 2007 Posts: 10,133 A Red State SNK-EYZ I Live Here
SNK-EYZ I Live Here Joined: Jan 2007 Posts: 10,133 A Red State	Quote: "A buddy of mine is wanting a set of recall wheels and so far he can't find a vendor that has any. From what he's been told they may not reproduce any more of them." http://www.specialtywheel.com/product-showcase/mopar/mopar-warrior-wheel.html He called Specialty Wheel and they didn't have any available and said they didn't plan on getting more. Kayse can't keep up at all now. lol

Re: Looking for Sand Casting company - any recommendation? [Re: SNK-EYZ] #1604454 04/09/14 04:14 AM 04/09/14 04:14 AM
Joined: Jan 2003 Posts: 27,468 So Cal autoxcuda Too Many Posts
autoxcuda Too Many Posts Joined: Jan 2003 Posts: 27,468 So Cal	There were 3 recall rims for sale at Spring Fling. Anyone know who got them? They looked like 15". Sorry I didn't get a picture of them. I was busy early in the morning.

Re: Looking for Sand Casting company - any recommendation? [Re: Stanton] #1604455 04/09/14 09:38 AM 04/09/14 09:38 AM
Joined: Feb 2003 Posts: 12,675 Columbia, CT M moper I Live Here
moper I Live Here M Joined: Feb 2003 Posts: 12,675 Columbia, CT	Quote: But you can't reproduce the cast finish with billet. No doubt billet would be the way to go if it were an option. But a single billet could be painted and finished correctly to reproduce an as-cast surface, accounting for the shrinkage factor, and a mold made out of that. Well, art is art, isn't it? Still, on the other hand, water is water! And east is east and west is west and if you take cranberries and stew them like applesauce they taste much more like prunes than rhubarb does. Now, uh... Now you tell me what you know.

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