Consolidated Casting Corporation used investment casting to solve a major issue in the supply chain of a key component.
Originally designed by the customer and their original supplier as a 2-piece investment cast manifold and cover assembly (top view), welded together by an outside sub-contractor and machined and pressure tested by a third party, resulting in a multitude of quality and delivery issues and finger pointing throughout the supply chain. The customer decided to look for a new supplier that could produce the entire assembly in house, in order to eliminate the problems in the supply chain.
Consolidated Casting Corporation (CCC) accepted the challenge to produce the complete assembly in house as it was originally designed, while it’s engineers helped develop a new, much more efficient, higher quality design (bottom view). CCC’s change to the new design incorporated a lower cost stamping in place of the cast cover, reduced the weight and cost of the (stainless steel) assembly, improved the stability, weld ability and quality of the product, reduced lead times and inventory, and ultimately saved it’s customer more than $300,000.00 per year in production costs. The components are cast, robotically welded, CNC machined and 100% leak tested at CCC.