MODIFICATION OF FOUNDRY MODELS FOR SPECIAL VEHICLES

Foundry models are designed to shape sand or earth molds, into which molten metal is poured to produce metal components once the mold is broken.

We developed a project for a company specializing in the production of special vehicles, specifically tasked with modifying some models used to create critical components such as the climbing gear housings located near the vehicle’s wheels and parts of the gearbox housing.

The project began with an accurate 3D scan of the existing models using the Artec Eva 3D scanner. This step allowed us to obtain a detailed digital reproduction of the original model. The digital file was then compared with the CAD model of the part the company aimed to produce.

By overlaying the 3D scan mesh with the CAD model, we identified the differences between the current model and the desired one. Instead of completely rebuilding the models from scratch, we designed and produced additional parts that fit perfectly with the existing geometry.

The additional parts were produced using rapid prototyping technology, specifically SLS (Selective Laser Sintering), which allowed us to create durable and precise nylon components. To ensure perfect adhesion, the model surfaces were sanded beforehand, improving the quality of the bonding.

To ensure precise positioning of the additional parts, we designed and created masks using a CNC milling machine. These masks allowed us to place the additional components with decimal precision, ensuring perfect alignment with the existing geometry.

Once the additional parts were secured, we smoothed the surface of the models using putty, eliminating any irregularities and ensuring an optimal finish.

At the end of the process, a new 3D scan was performed to verify that the modified models were perfectly aligned with the required specifications. This final check ensured that every part was ready for the subsequent foundry process, meeting the precision and quality standards set by the client.

Thanks to an integrated approach combining 3D scanning, rapid prototyping, and the use of CNC milling technologies, we were able to optimize the foundry models for the production of special vehicles. This process reduced time and costs while ensuring maximum precision, which is crucial for complex components such as climbing gear housings and gearbox parts.

The innovation and precision in our approach allowed us to achieve an impeccable result, fully meeting the client’s needs.