Iron Casting Design Collaboration Yields Real Results

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

Additive Manufacturing, also known as 3-D printing, streamlined casting design to production and revolutionized the way Waupaca Foundry delivered value to its customers and solves supply chain risk. The iron casting supplier installed its first sand 3D printer in 2022 to automate core production and create one-piece complex cores that were once multi-piece assemblies.