The task of designing the foundry tooling from the CAD model was not an easy task. There were 44 individual pieces of sand than required to be assembled to create the cavity in the mould for the metal. Each of these pieces of sand required a separate tool, some with many individual pieces.
The tooling was CNC machined from a synthetic model board. These were then fitted together and finished off by skilled Patternmakers to complete each individual tool until the complete suite of tools were finished. A
All the tooling was inspected via CMM (Co-odinate Measuring Machines) to ensure the tooling was accurately produced compared to the CAD design.
The tooling design and manufacturing was complete late 2012 and the first casting produced just before Christmas.
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