Product Optimization Through Transition to Lost Wax Casting

Leading customer in the pump and valve industry with low-weight steel sand casting parts.
Annual volume of parts was low, making traditional steel sand casting economically unfeasible.

Existing steel sand casting process had high material wastage and extensive machining requirements.
Low production volumes increased per-unit costs beyond the customer’s target pricing.
Product surface quality and dimensional accuracy required enhancement to match functional needs.

Comprehensive review of the customerʼs drawings, production requirements, and cost targets.
Advised converting the parts from steel sand casting to the Lost Wax Casting (Investment Casting) process.
Justification for lost wax investment casting :
o Superior dimensional accuracy and surface finish compared to sand casting.
o Ability to produce near-net-shape parts reducing post-cast machining.
o Feasible for small batch sizes with complex geometries.
o Reduced raw material and machining costs.

Redesigned parts to optimize for lost wax casting capabilities and minimize machining.
Developed wax patterns and ceramic shell molds per customer specifications.
Employed precise thermal processing to reduce defects and improve metallurgical properties.
Incorporated best practices in shell mold preparation to ensure consistency.

Cost Reduction: Approximately 35% cost savings compared to original sand casting and machining processes.
Improved Product Quality: Enhanced surface finish, dimensional accuracy, and reduced internal casting defects.
Material Savings: Reduced machining scrap and optimized raw material usage.
Customer Pricing Satisfaction: Met customerʼs target price while maintaining performance and quality.
Feasibility for Low Volume Production: Enabled economical production for annual volume through lost wax process adaptability.

AMSOL strengthened the partnership by delivering a more cost-effective and higher quality casting solution.
Enhanced customer satisfaction due to consistent quality and competitive pricing.
Established AMSOL as a proactive partner capable of technical consulting and product optimization.