CPM Industries' Blog

CPM's Competitive Advantage

Posted by Gavin Mason

Competitive Advantage in Sand Casting

By definition, competitive advantage means "a condition or circumstance that puts a company in a favorable or superior business position." After 3 generations of ownership and 50+ years in business, we believe we have developed a distinct competitive advantage over many of our competitors. Our competitors can be grouped into four groups because our competitive advantage allows us to compete in several markets. Our competitors are either a foundry, pattern shop, machine shop, or any combination of the three. 

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Tags: Aluminum Castings, CPM Industries, cnc machining, competitive advantage, turnkey castings, machined sand casting supplier, pattern and machine shop

Castings Found on a Vehicle

Posted by Gavin Mason

Metal Castings on your Vehicle

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Tags: Aluminum Castings, Magnesium Castings, Aluminum Sand Casting, casting, castings, diecasting, metal castings, cast iron, aluminum, magnesium

CPM Industries' Unique Casting Process

Posted by Gavin Mason

Our Unique Process Explained

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Tags: Aluminum Castings, CPM Industries, casting process, Prototype castings, foundry, aluminum, magnesium

Does Your Casting Have a Sweet Tooth?

Posted by Gavin Mason

Simple Sugar may Solve Complex Problem 

The foundry and metal casting industry is a multi-billion dollar industry with foundries of all shapes and sizes located throughout the world. Metal castings can be dated back to before the Roman empire and were used to develop weapons and tools as well as being critical in the development of human civilization. The most common method of casting is known as sand casting and involves using sand to hold the shape of a part. Once the sand is in the shape of the part to be casted, molten metal is poured into the sand mold forming the final part. If you are like me, the first time I heard of this process my first question was, "so how does the sand stay in place with molten metal being poured into it?" 

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Tags: Casting Design, Aluminum Castings, Sand Casting Design Improvements, Aluminum Sand Casting, Green Sand Casting Method, Prototype Sand Castings, Quality Control of Sand Casting, sand casting, Magnesium Sand Casting, casting

Cast vs. Billet

Posted by Gavin Mason

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Tags: Casting Design, Aluminum Castings, Aluminum Sand Casting, CPM Industries, casting, CNC, Aluminum Hog-Outs, Billet

3 Types of Cores Used to Make Sand Castings

Posted by Tim Carlstedt

How are hollow passage ways or special features put into a casting?


Through the Use of Cores that are Placed into the Mold Box!! 

In this part 1 of 2, we will discuss the common names and terms for Cores and Coreboxes that are used in the horizontal green sand casting method.  At CPM Industries, we often use Cylinder Cores, Balanced Cores and Dovetail Cores with Patterns to create the necessary passageways to meet the component's characteristics.  The article below discusses three types of cores that are placed on the parting line of the casting.

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Tags: Ductile Iron Castings, Casting Design, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Sand Casting Design Improvements, CPM Industries, Green Sand Casting Method, Casting Knowledge, Pattern/Foundry Tooling

What is a Rapid Prototype Aluminum Casting?

Posted by Tim Carlstedt

What is the difference between a Rapid Prototype Aluminum Casting versus an Aluminum Hog-Out?  Also, why would you choose one over another?  Well let’s clarify what each is:

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Tags: Aluminum Castings, Aluminum Sand Casting, Prototype Sand Castings, Aluminum Hog-Outs, Rapid Prototype Castings, Rapid Prototype Aluminum Castings

Aluminum Sand Castings: Foundry vs. Finished Casting Supplier

Posted by Tim Carlstedt

  One determination that all Aluminum Sand Casting buyers must consider is whether their project is best suited to be manufactured at either an Aluminum Foundry or a Finished Aluminum Casting Supplier.  There are a lot of little aspects that go into this decision such as: Quantity, Delivery Time, Material, Machining Capabilities (if necessary), and (for obvious reasons) Quality.  So, let’s distinguish the difference between the two supplier options. 

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Tags: Aluminum Castings, Aluminum Sand Casting, Green Sand Casting Method, Turn-Key Sand Cast Components, Aluminum Sand Castings

Benefits of Aluminum Sand Castings?

Posted by Tim Carlstedt

Ever wonder what makes Aluminum such a popular choice for sand castings?  While there are a ton of factors that go into that decision, here is a list of the 6 reasons why Aluminum is chosen for so many different applications.

    1. Low Density

      1. Weighs 1/3 of Steel
    2. Good Conductor of Electricity

    3. Non-Combustible  and Non-Magnetic

      1. These traits are excellent and make the alloy invaluable for projects that involve electronics
    4. Non-Toxic

    5. Malleable/Ductile

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Tags: Aluminum Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Tips for Design Sand Castings

Sand Casting vs. Investment Casting

Posted by Tim Carlstedt

What are the advantages and disadvantages between the Green Sand Casting Method and the Investment Casting Method?

This is a common question for the metal casting industry and CPM wanted to shed some light on the subject.  In this entry, we will first look at a comparision of the two different methods, followed by a explanation of the table, then lastly another table highlighting the advantages and disadvantages of each method in comparison.

 

Comparison of Green Sand Casting vs. Investment Casting

 

Green Sand Casting Method

Investment Casting Method

Relative Cost in Quantity

Low

Highest

Relative Cost for Small Number

Lowest

Medium

Permissible Weight of Casting

Unlimited up to approx. 1 ton

Ozs to 100 lbs.

Thinnest Section Castable (Inches)

1/10

1/16

Typical Dimensional Tolerance (Inches)

.012

.01

Relative Surface Finish

Fair to Good

Very Good

Relative Mechanical Properties

Good

Fair

Relative Ease of Casting Complex Design

Fair to Good

Best

Relative Ease of Changing Design in Production

Best

Fair

Typical Base Tolerances

+/- .040 – 1.00 in

+/- .003 - .008 in

Typical Surface Finish

150 – 350 RMS

63 – 125 RMS

Minimum Wall Thickness

.140 - .250 in

.094 - .187 in

Typical Tooling Cost

$800 to $5,000

$3,000 to $10,000

Well, WHAT DOES THAT MEAN TO ME?!

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Tags: Ductile Iron Castings, Ductile Iron Sand Casting, Casting Design, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Casting Knowledge, Secondary Machining, Finished Surfaces, Prototype Sand Castings, Pattern/Foundry Tooling, Patterns for Sand Castings, Cast Iron (Gray) Sand Casting, Investment Casting Method

Ranking Machinability of Sand Castings

Posted by Tim Carlstedt

    Machining a Sand Casting is a major cost contributor in a project that involves a finished casting. The major factors to in determining Machinability are the alloy's hardness (meaning softer is better), how long the cutting tool will last, and time it takes (includes labor) to complete all the operations in machining. 

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Tags: Ductile Iron Castings, Ductile Iron Sand Casting, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Secondary Machining, Cast Iron (Gray) Sand Casting

CPM Example: Finished (Machined) Aluminum Casting

Posted by Tim Carlstedt

Want to see another example of CPM's capabilities? 

Pictured below is a Finished (Machined) Pipe made from an Aluminum Sand Casting for the Automotive Industry.  Our processes allowed us to take this project from start to finish in order to provide the customer with a part that was ready for testing.  To go into the process a little more, CPM was given a solid model, from which we designed and manufactured the pattern with necessary cores, got the castings, and fully machined it so it was ready to go for assembly!

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Tags: Aluminum Castings, Aluminum Sand Casting, Secondary Machining, CPM Industries' Example

Sand Casting vs. Other Casting Methods

Posted by Tim Carlstedt

    There are several methods that are used to produce a casting.  But what are the general differences and characteristics of the Methods?  Here is a table that represent that highlights the key differences between the Green Sand, Precision Molding, and Chemically Bonded Molding casting methods. 

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Tags: Ductile Iron Castings, Ductile Iron Sand Casting, Casting Design, Aluminum Castings, Cast (Gray) Iron Castings, Magnesium Castings, Aluminum Sand Casting, CPM Industries, Green Sand Casting Method, Casting Knowledge, Cast Iron (Gray) Sand Casting, Magnesium Sand Casting

A CPM Example: From CAD Model to Finished Aluminum Sand Casting

Posted by Tim Carlstedt

A Look into CPM's Turn-Key Capabilities for an Finished Aluminum Sand Casting!

    We were recently asked to show an example of a Turn-Key Cast Component that we have made here at CPM Industries.  So, why not share it with the world!  What does Turn-Key mean to us?  This means that the project will go from Engineering Assistance, Pattern Tooling, Casting, and Secondary Machining.  We also perform any other additional testings that may be required.

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Tags: Casting Design, Aluminum Castings, Aluminum Sand Casting, Casting Wall Thickness, CPM Industries, Secondary Machining, Finished Surfaces, Pattern/Foundry Tooling

Aluminum Plaster Casting? What is that?

Posted by Tim Carlstedt

  Recently, I was asked to describe what Plaster Casting was and the benefits of using this method.  What a perfect topic!  At CPM, we provide Aluminum Plaster Castings primarily to Simulated Die Casting in Short Runs of 15-30 for Prototyping and Testing Operations. For runs of 1 or 2 parts, then it is often best to go with a Rapid Prototyping such as a SLA.

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Tags: Casting Design, Aluminum Castings, Aluminum Sand Casting, Simulated Die Casting, Plaster Casting Method, CPM Industries, Casting Knowledge, Prototype Sand Castings, Pattern/Foundry Tooling

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