The form design is equivalent to a later series solution: all cores and molds are conventionally produced in the same way.
The sand process is used to save time and costs compared to expensive tools.
Purpose: Prototype of a racing intake manifold
Challenge: Many undercuts and cores, complex design
Solution: Splitting of the mould into four parts without any consideration of undercuts and distortions.
As an alternative to the conventional construction the 3D printing is an excellent choice.
By using the layer building method the risks of multi-core breakage during assembly,
rework costs increased by unclean core segment and impacts on sand casting error are avoided easily.
Purpose: An alternative to the conventional construction.
Challenge: Multi-core breakage during assembly and rework costs increased
by unclean core segment and impacts on sand casting error.
Solution: good surface from casting = good efficiency, faster production