Reducing component weight has multiple benefits, but choosing the best lightweighting strategy requires the right partner. Waupaca Foundry offers manufacturers the clear advantage, whether their motivation is to cut material costs, meet CAFE standards or improve strength and assembly ergonomics.
Waupaca Foundry ductile iron and HNM™ Series high-strength ductile iron solutions offer advantages compared to alternative material solutions. Cast and machined iron casting components are less expensive, stronger and smaller than aluminum parts, yet support thin wall structures and meet complex shapes. A single ductile iron casting for example can replace several weldment parts to simplify assembly and reduce manufacturing costs. Waupaca Foundry design and tooling engineers collaborate on iron casting designs for durable, cost-conscious parts that achieve even the most aggressive lightweighting and mass targets.
Lightweighting isn’t just for the automotive industry. Commercial vehicle, off-highway and oil & gas manufacturers trust Waupaca Foundry for weight and mass reduction solutions too.
Click on the case studies below to discover how Waupaca Foundry has helped OEMs and their Tier 1 suppliers reduce weight and metal component costs while improving component performance, simplifying assembly and more.
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.
High-Strength Ductile Iron Control Arm Meets Lightweighting Objectives
Aluminum components are often utilized for their lightweight capabilities in the automotive industry. However, Waupaca Foundry, in collaboration with Hitachi Metals America, successfully converted the Ford CD4 platform lower control arm from aluminum to high-strength ductile iron, not only achieving weight and cost savings for the company but also relieving the company’s supply chain that was facing disruption due to the high volume of production.
Trends in Lightweighting with Metal Castings
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3-ways vehicles are reducing weight
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