Customer Requirement & Initial Situation
- Customer from Pump & Valve industry approached AMSOL with drawings for Steel Sand Castings.
- Key challenges identified:
- o Parts were light in weight.
- o Annual volume was low, making it unfeasible for conventional steel foundries.
- o Risk of high cost per piece and inconsistent quality.
Challenges in the Project
- Low-volume + low-weight parts are not economical for sand casting processes.
- Customer needed competitive pricing while maintaining reliability and surface finish.
- High machining requirements in the original design increased cycle time and material wastage.
AMSOL’s Engineering & R&D Solution
- Conducted product evaluation & feasibility analysis of the drawings.
- Recommended process conversion to Lost Wax (Investment) Casting.
- Modified designs to:
- o Reduce overall machining.
- o Optimize material usage.
- o Ensure consistent dimensional accuracy.
- Implemented better moulding process to improve surface quality.
Execution Steps by AMSOL
- Studied customer’s drawings & application requirements.
- Converted design to be feasible for lost wax casting.
- Developed tooling suitable for low-volume precision casting.
- Optimized machining allowances to minimize cutting operations.
- Validated final samples for fitment, strength & surface finish.
- Achieved customer’s target pricing with improved product quality.
Achieved Results
- Reduced overall machining time and cost.
- Achieved higher surface finish compared to sand casting.
- Delivered economical solution for low-volume production.
- Saved raw material cost by optimizing design and process.
- Successfully met customer’s target price and quality expectations.
Customer Benefits
- Received a cost-effective solution that was not feasible in traditional foundries.
- Access to higher-quality surface finish with precision casting.
- Reduced total cost of ownership through material and machining savings.
- Reliable supply chain for low-volume, high-precision components.
AMSOL’s Value Proposition
This project demonstrates AMSOL’s strength in:
- Design evaluation and optimization before production.
- Choosing the right manufacturing process based on feasibility.
- Delivering cost, quality, and lead-time improvements for niche requirements.
- Acting as a true engineering partner for customers in the pump & valve industry.