From Sketch to Shipment: A Step-by-Step Guide to Foundry Collaboration

Step 1: Concept & Design Development

Define Requirements: Determine dimensions, material specifications, weight, and performance needs.

Sketch & CAD Model: Create a detailed 2D sketch or 3D CAD model (SolidWorks, AutoCAD, etc.).

Prototype Design: Use rapid prototyping (3D printing or CNC machining) to validate design feasibility.

Material Selection: Choose appropriate alloys (e.g., aluminum, cast iron, or steel) based on thermal conductivity, strength, and cost.

Step 2: Foundry Selection & RFQ (Request for Quotation)

Research Foundries: Identify foundries specializing in compressor housing casting.

Request Quotations: Send an RFQ detailing specifications, tolerances, order volume, and quality requirements.

Assess Capabilities: Ensure the foundry has expertise in sand casting, investment casting, or die casting, depending on your needs.

Step 3: Tooling & Mold Making

Pattern Design: Develop patterns for sand casting or molds for die casting.

Prototype Casting: Create a small batch for initial testing.

Mold Testing & Adjustment: Conduct trials to refine mold dimensions and reduce defects.

Step 4: Casting & Production

Metal Preparation: Melt and pour the selected alloy into the mold.

Solidification & Cooling: Allow the metal to cool and solidify.

Shakeout & Cleaning: Remove casting from the mold and clean excess material.

Heat Treatment (if required): Improve mechanical properties through stress relieving or annealing.

Step 5: Machining & Finishing

CNC Machining: Mill, drill, and finish critical areas to precise tolerances.

Surface Treatment: Apply coatings like anodizing, powder coating, or plating for corrosion resistance.

Quality Control: Inspect for porosity, dimensional accuracy, and defects using X-ray, CMM, or ultrasonic testing.

Step 6: Assembly & Final Inspection

Component Assembly: If required, assemble additional parts (seals, bearings, etc.).

Leak & Pressure Testing: Ensure no air or fluid leakage occurs in the housing.

Final Inspection: Confirm compliance with ISO, ASTM, or customer-specific standards.

Step 7: Packaging & Shipment

Custom Packaging: Protect components with foam, wooden crates, or vacuum-sealed bags.

Logistics Planning: Arrange air, sea, or land transport based on cost and urgency.

Delivery & After-Sales Support: Provide tracking details and technical support post-shipment.