A manufacturer of dust filtration systems for heavy agriculture and construction vehicles was experiencing significant product failures with a sand cast component. The harsh operating conditions of farm and construction equipment demanded exceptional durability from dust filtration components.
The Problem
- Frequent breakage: Sand cast aluminum static fans were failing during transport and under operational stress
- Inconsistent quality: Porosity and non-uniform material density in sand castings created weak points
- Performance issues: Rough surface finishes from sand casting were impacting airflow efficiency in dusty environments
- Customer complaints: Field failures were damaging the manufacturer’s reputation with equipment OEMs
The customer needed a static fan that could withstand the demanding environment of heavy equipment while maintaining optimal dust filtration performance.
Solution
Glocon completely reimagined the part design and manufacturing approach, transitioning from sand casting to precision pressure die casting.
Our Approach
- Design for Manufacturing: Redesigned the static fan geometry to optimize it specifically for pressure die casting
- Process Upgrade: Implemented high-pressure die casting to eliminate porosity and achieve uniform material density
- Surface Optimization: Leveraged die casting’s superior surface finish capabilities to enhance airflow performance in dusty conditions
- Quality Enhancement: Established consistent, repeatable production with minimal variation
Results
The pressure die cast static fan delivered dramatic improvements across all performance metrics:
- Eliminated breakage issues: Zero failures reported during shipment and significantly reduced field failures
- Superior material integrity: Uniform density throughout the casting eliminated weak points and porosity-related failures
- Enhanced dust filtration efficiency: Smooth die cast surface finish improved static fan airflow performance in challenging dusty environments
- Consistent quality: Repeatable process delivered uniform parts with predictable performance characteristics
Why This Matters
This project showcases Glocon’s ability to solve quality and durability challenges through strategic process selection and design optimization. By transitioning from sand casting to pressure die casting and redesigning the part accordingly, we transformed a problematic component into a reliable, high-performance solution that exceeded customer expectations.