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   Spin-Casting Replaces Machining For Functional Parts



The left-hand piece in each pair of parts below was originally sand cast and machined. In the moderate volumes required, the cost per piece was high. The manufacturer set up a TEKCAST centrifugal Spin-Casting equipment system. The rubber molds reproduced all parts with such good fidelity and precision that all machining except internal thread tapping was eliminated. Even the gear teeth required no further machining. Molds were set up at a cost of about $80 per mold (including labor) to cast several different parts simultaneously and each mold could be cycled about 200 times. As a result, final cost of the parts after all costs were factored in were 600% lower than the previously sand cast and machined parts.


   Spin-Casting Reduces Costs For Lift Truck Manufacturer


These cams and levers for electro-pneumatic controls of fork-lift trucks were originally machined and/or welded from steel and aluminum. The larger part cost over $25 each in the relatively low quantities required. The manufacture set up a TEKCAST Spin-Casting equipment system. Reproducing these and similar parts in a commercial grade zinc alloy with a tensile strength about the same as aluminum, brass and low-grade steel. Both parts shown here have been Spin-Cast. Machining has been reduced to just drilling and tapping. Today, cost of the larger part is under $1 in quantities of 600, while the smaller part costs less than $.10 in 1000 - piece lots. Savings generated by Spin-Casting these and similar parts paid for the entire TEKCAST system within two months.


   Solve Import Problems With Rubber Mold Spin-Casting


Clamps such as these are used in laboratories around the world. Recently, in one country the change in foreign exchange rates and increasing import regulations greatly reduced the ability of the importing firm to meet its customers needs. The decision was made to explore manufacturing locally. Parts were submitted to the TEKCAST distributor, who utilized his own TEKCAST system to make samples which showed the feasibility of producing these and many other parts by Spin-Casting. With a low investment in a TEKCAST Spin-Casting system, the importing company is now able to meet its customer needs on these items and many other types of laboratory hardware, without tying up large amounts of capital in foreign sourcing.


   50 Plastic Sets Rushed For New Blower Using RTV Rubber


A major U.S. electric motor and blower manufacturer, on a rush basis, had to make 50 operating models of a new, large, high efficiency blower. 50 plastic sets - 4 parts per set - would take their model maker 8 - 10 weeks to produce at a cost of $12 - $15,000. To save time and money, the company wanted to Spin-Cast these plastic injected-type components. The original plastic patterns were too fragile for the normal high-pressure, heat cured vulcanization process. Three Spin-Casting molds were made from RTV Rubber (Room Temperature Vulcanizing Silicone) by pouring the liquid catalyzed RTV rubber compound over the plastic patterns. The molds fully cured within 24-hours. The blower components were then Spin-Cast in the RTV molds with a high strength, quick-setting liquid polyurethane. Each part was demolded within 5 to 6 minutes. The entire project was completed in under 4 days.


   Small Company Enters Lucrative Automotive After-Market


In this era, older cars are increasingly cherished, while the original manufacturers seem less desirous of keeping them running. One person studied this market - noting the size, type, and quantities of parts that seemed to be in frequent demand. Analysis of the parts showed two major groups: decorative, such as hood ornaments: and functional, such as door handles. Further evaluation showed that many automotive parts could be made using a commercial grade zinc alloy and were of a size that could readily be made by Spin-Casting. Those that needed plating could easily be sent to a local plater. The person purchased a complete TEKCAST system, and set it up in a rented garage. For an investment of less than $20,000 he began a successful "hard-to-find" auto-parts, mail-order business.


   Fast, Low Cost Prototyping of a New Design Mock-Up


A major U.S. door-and-window manufacturer wanted to evaluate a large number of prototypes of a new latch design in both plastic and zinc. Other processes would have required a very expensive master pattern, or costly machining. Instead, to make a pattern for a Spin-Casting rubber mold, they simply assembled a plastic pattern by pinning and gluing together pieces from 3 different existing plastic injection-molded production parts. In one mold, which cost less than $50 for materials and labor, they cast both a zinc alloy and a thermoset plastic. The parts were functionally similar to conventionally produced zinc die cast and plastic injection molded production parts eliminating enormous tooling expense and long lead times. For this application, TEKCAST's Centrifugal Spin-Casting system provided 250 parts/hr. in plastic and over 1000 parts/hr. in zinc. Either way, they can now produce their 60,000 - piece per year requirement without investing in expensive die casting or injection molds.