Collaboration That's a Cut Above
Collaborating with a global leader in commercial turf and lawn care equipment, Waupaca Foundry worked to drive out costs from a mower bumper cast in gray iron, and thereby enhanced the zero-turn commercial mower’s performance.
Risk Avoidance and a Fast Turn with 3D Printing
Waupaca Foundry leveraged 3D printing to provide an improved casting design 2-3 weeks ahead of the customer’s lead time. This solution offered the customer flexibility to test the design faster, mitigated risk, and provided a cost savings.
Lightweighting Achieved Through Design Optimization and High-Strength Ductile Iron
Waupaca Foundry in collaboration with Hitachi Metals design engineers developed a solution to meet weight reduction requirements by redesigning and optimizing the shape of the part using a high-strength ductile iron material.
Lightweighting Through Redesign Furthers Fuel Economy Goals
An automotive OEM diligently working to meet government-mandated fuel economy goals sought Waupaca Foundry to achieve its lightweighting objectives. The targeted component is a differential carrier in the driveline on the company’s light duty trucks already in production.
Weight Reduction Through Collaboration
The goal was to optimize the design of an advanced helical differential case for the successor to the world’s first commercially available four-wheel drive vehicle. This was a challenge that would fascinate even the most experienced engineer.
Conversion to Ductile Iron Improves Durability and Eliminates Warranty Claims
To improve durability and wear of components assembled on commercial zero-turn mowers, Waupaca Foundry collaborated with both the machining supplier and the OEM. In short, multi-piece steel weldments were converted to single ductile iron castings.
Conversion Transforms 10-Piece Weldment to Single Gray Iron Casting
A recent design project with the world’s largest agricultural equipment manufacturer shows what working together on casting designs can accomplish. Our customer needed a stronger, lighter alternative to the 66 pound, multi-part weldment used in their equipment. The old model was heavy and awkward to work with. It needed a makeover
Out-of-the-Box Thinking Leads to Robust Feeder Housing Assembly
Using lessons learned from a past design success, Waupaca Foundry collaborated with a global leader in farm equipment and ag technology on a high-capacity combine. Our recommendation for a solution was somewhat counter-intuitive—increase the number of parts on the feeder housing assembly.
Closed-Loop Cooling Water Works
At Waupaca Foundry, we have a 10-year vision for expanding our sustainability practices with achievable goals for reducing our environmental impact.
ECO-PARK Created with Foundry Sand
Thousands of tons of foundry sand that could no longer be reconditioned and reused to make molds avoided the landfill and was instead put to good use. That sand is now benefitting the community of Waupaca, Wisconsin through a unique development project.
Local Population Reaps the Benefits of Repurposed Sand
Etowah, Tennessee, is home to Waupaca Foundry Plant 6. It is also home to a lot of cows. The care of the bovine population had become increasingly difficult for the McMinn County dairy farmers due to the scarcity of affordable sand bedding.
Utilities Benefit From Foundry By-Product
Once upon a time, foundry slag had a boring reputation. Its unglamorous name was synonymous with unwanted leftovers. You could imagine it as the unfortunate, unusable “eggshells” tossed away after the “omelet” was made, relegated to linger in landfills.