The client already had the 3D CAD data for the housings which we received and imported into our 3D CAD software Solid Works. With the short time frame required by the client, the most efficient manufacturing methods needed to be decided. With speed of manufacture and accuracy as the two main considerations. It was decided that the best method to use was to firstly SLS rapid prototype the gearbox housings. This SLS model could then be used to create a ceramic mould for the rapid investment casting process. Production of the aluminium casting followed at a subcontractor foundry. CNC machining in house of the high precision features completed the parts ready for assembly and test at the vehicle manufacturer.
SLS Rapid Prototyping
For the first process of SLS rapid prototyping the 3D CAD data received from the client had to be modified with material added on in certain places that would need to be machined later. These modifications were all done in Solid Works,our 3D CAD software,and once finalised the SLS rapid prototype models were made.
These were then inspected with our CMM (co-ordinate measuring machine) to ensure the accuracy of the housings. From here ceramic moulds for each housing could be produced. These moulds were then used for the rapid investment casting process. The aluminium castings of the housings were then given to our CNC engineers where they used the 3D CAD data used to make the SLS models and the original CAD data from the client. Here they could import both sets of CAD into our CAM software Power Mill to work out the areas of the casting that needed machining. Then each casting was machined on our CNC machining centre to match the clients data, from here the finished castings were fully inspected with our CMM to make sure it met our clients quality requirements whilst meeting the delivery schedule.
