Casting: Large-scale tooling made from cast aluminium

One should first point out that there is a strong tendency to manufacture ever-larger parts (especially car body parts) as single pieces. After all, the fewer components that have to be joined together, the easier and quicker – and more economical – the installation.

This development is leading, however, to ever more complex component geometries. This is placing increasingly greater demands on the tooling required to manufacture the parts. In order to fulfil these demands, the dimensions of the tools have to become larger and larger: they need to be able to shape parts that are as large as possible and incorporate ever more functions.

Such large tools can also be made as aluminium castings. High demands are placed on the foundry as the geometry of the large-scale tools is extremely complex, of course. The large dimensions of the casting and its usually large wall thicknesses require a well-thought out approach to the casting process in order to avoid shrinkage cavitation.