the Stuart McElrath Company
since 1994

The Stuart McElrath Company can reverse engineer parts or equipment for the purposes of documenting vintage parts, acquiring new sources of manufacturing, improving reliability or reducing costs.
SMC | Casting Design
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SMC can work with customers' to convert their existing parts, or design concepts, into a casting for superior strength and lower costs in large quantities. SMC will take the part or design and add the appropriate drafts and radii while keeping an eye on cross-section thickness, junctions and parting lines. SMC uses 3D CAD software to provide the modeling for the design process.
Casting Design    
SMC has many contacts in the foundry industry. Once the casing design is finished, we will work the customer to have the necessary patterns and core boxes made. Once the patterns and core boxes are made, SMC will work with the customer's foundry, or recommend one, for casting sampling and production runs.
Design Considerations     Draft Angle
Undercuts & Cores
Parting Line
Corners & Angles
Wall Thickness
Cross Sections
Junction Design
Casting Allowances
Foundry Process & Production Equipment
During the design, consideration must be given to the foundry processes used to make the casting; typically Nobake, Green or Shell Sand, but there are many others. Pattern and core box design are very dependent on both the foundry process and the equipment use in casting production.

Once the patterns and core boxes have been made, a small sample run will need to be preformed to insure the poured casting is as desired for machining. It's not uncommon to repeat this process several times before larger production quantities are ordered.