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 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.
Reshoring Helps Home Fitness Company Meet Consumer Demand
A U.S.-based fitness equipment manufacturer localized three new assembly and manufacturing lines, as well as a majority of its parts and component supply chain. Ballooning consumer demand for at-home exercise accessories strained its off-short supply chain. Partnering with Waupaca Foundry as its casting supplier allows the company to save money and streamline assembly processes within the United States.
Innovation and Problem-Solving Mitigate Supply Chain Risk
Through collaborative engineering and a prototype 3D-printed core assembly, Waupaca Foundry provided a solution that could improve quality, delivery and cost for a compressor body already in production. It also meant reliably changing the iron casting manufacturing process from horizontal to vertical molding, as well as reshoring the part to a U.S. supply base—with complete peace of mind.
Industry Collaboration Leads to Groundbreaking New Product Development
Oil Tool Solutions (OTS) originally sought out a domestic supplier to develop and produce its Hulk clamp used in down-hole oil production. Once in discussion with Waupaca Foundry, OTS changed course in order to expand in new markets by redesigning and creating a smaller-diameter and longer, second-generation clamp.
First Cast-Iron Backhoe Bucket on the Market
Waupaca Foundry aided in the redesign and launch of the first-to-market cast iron bucket attachment for a compact utility tractor attachment OEM. After an innovative and collaborative design and problem-solving process, the resulting backhoe bucket and teeth are more durable, cost-effective, and made in the United States.