Casting Intercooler End Tanks – A Day at the Pattern Shop!

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The photo above shows the machining of the TMIC outlet end tank master. The Bottom received a finishing pass and then the part was flipped so that the top could be roughed out. When all is done, this will be a flawless part. Now that the master parts for both end tanks have been completed, we’ll make a cast iron match plate from each of them. You probably noticed that it looks a lot like they’re being machined from wood and that’s because they are! These master parts will only be used a single time – to cast the real molds from, so a heavier duty material only costs more and takes longer, with no added value.

Interesting Note: The master that you see here is not dimensionally identical to our final part – it’s actually larger. Based on the foundry’s preferences, standard shrink allowances and the geometry of the model, the pattern makers job is to determine how much the cast aluminum part will shrink/contract during solidification. An easy way to cut cost, especially if you’re casting overseas, is to skip this step. Ever had an application-specific intercooler that didn’t fit quite right? There’s a decent chance that uncontrolled shrinkage was at least partially to blame.

For those unfamiliar with high end casting processes, creating the tooling and molds is the giant hurdle standing between your design in CAD and real parts. With properly designed and manufactured tooling, casting and machining the parts is relatively straight forward. One of the many benefits of casting right here in Minnesota is that we’re able to sit down with everybody involved and work through potential issues to mitigate the risk of trouble during production almost entirely. That means lower production cost for us and lower pricing for you!