Need Help Reproducing Cast Parts

[bulletpruf]

Fellas -

I'm in need of some clutch covers for some of my Jonsered XF's (pictures below). Figure I would do 10-20 so I have a few spares and some to sell to other collectors. Have done some preliminary research, but could use some input from some of the smart folks here. Here are my initial thoughts:

CNC Machining: Making this part from a billet would be cost prohibitive, and difficult, given thickness and shape.

Casting in Aluminum: This is something I could potentially do in my garage, if I had the time, but I don't (too many projects to complete before we move back to the US in a year). Smaller foundries (Cattail recommended by a lot of folks - Amish foundry in PA) can potentially do this, but they need a good part to make the mold from (I have this), they may want to thicken it up a bit to make it stronger and easier to cast (that's fine as long as the exterior is accurate), and they have to account for shrinkage of a few % when the metal hardens.

Additive Machining: Metal deposition process similar to 3D printing, but done in metal. You need to supply a CAD file (done with a 3D scan and then cleaned up by CAD operator), but you should end up with a part that's the right size and shape. I just have no idea on the cost of a 3D scan or the actual additive machining of each part.

Did I leave out anything? Any thoughts on the above processes? Prices?

Thanks!

Scott

 

[Deleted member 149229]

I do know just before I retired that 3D was pricey. A good foundry can really put out outstanding work with a minimum of machining.

 

[brandonstc6]

It was most likely cast in a high pressure die and it will have to be much thicker to be cast in a sand mold or a iron mold.


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[bulletpruf]

Thanks for the input. My nephew is going to take this project on. He's about to start his senior year in mechanical engineering at OU. He wants to create a CAD file and will see if he can have the part machined.

Scott

 

[ironman_gq]

Have it 3D scanned and look into lost wax casting. They can 3D print the parts in plastic which can be used (using the right plastic) exactly the same as lost wax molds. Basically they pour plaster around the part and the molten aluminum burns it out when it's poured. Very good detail and with the 3D scan of the part they can manipulate the models to make them however you need them to be.

 

[bulletpruf]

Have it 3D scanned and look into lost wax casting. They can 3D print the parts in plastic which can be used (using the right plastic) exactly the same as lost wax molds. Basically they pour plaster around the part and the molten aluminum burns it out when it's poured. Very good detail and with the 3D scan of the part they can manipulate the models to make them however you need them to be.

Thanks, Ironman. I'll look into that.