FEINGUSS BLANK GmbH

Weight savings is essential in racing. The competitive advantage can be gained with the best, light weight design. Every gram that can be saved on the racing car can make it faster and more agile. Victory or defeat can be determined by only one millisecond. FEINGUSS BLANK developed the best investment casting solution for such a racing car using the "Digital Twin" performance package. As part of a manufacturing cooperation and using our know-how, FEINGUSS BLANK was able to significantly reduce the component weight. FEINGUSS BLANK has recently developed and successfully implemented this service package to our customers. Thanks to new technologies, an investment casting part can be fully optimized by utilizing the Digital Twin package before a single part is manufactured. The Digital Twin by FEINGUSS BLANK is the key to sustaining customer added value. By implementing modern simulation methods, it is possible to simulate the essential steps in production and identify and eliminate possible concerns at an early stage.
 
The "Digital Twin" service package includes the following features, among others:

- Material simulation: What is the right material and heat treatment for the respective application?
- FEM calculation: Does the component withstand the application loading?
- Casting and solidification simulation: Can the component be easily and economically casted?
- Topology optimization: Can the geometry be optimized according to the loads and the casting process?

By means of these simulations, material recommendations, feasibility analysis, and part optimizations can be determined for the customer. Based on the findings of the Digital Twin, the following investment casting process can be realized:

- a safe, economical process through recognition and utilization of cost saving potentials
- complex geometries and the processing of difficult materials
- reduction of processing efforts through highest casting precision combined with intelligent lightweight construction
- reduction and minimization of development times
- weight optimization and reduction of material usage
- reduction of development and production startup costs

The advantages of the Digital Twin by FEINGUSS BLANK are obvious:
Different versions or iterations can be digitally tested finding the best possible option. The concept is reinforced by utilizing various methods of additive manufacturing. Once the design has been fixed, advanced samples and/or prototypes can be quickly produced using 3D printing technology. Cost-intensive tool production is no longer necessary. This combination of digital preparation and rapid availability of the initial components makes the difference. This saves development time and costs while significantly reducing the time to market introduction.

In addition to cost savings, our customers benefit from project security by having a reliable, competent development partner. Originally, the wheel carrier, which was part of the development project in the production cooperation, was fully machined. Now, with the help of our development know-how and corresponding simulations, the optimized casted geometry was developed based on application loading and further enhanced for the casting process.

•  Lightweight solution for motor racing

Who would have thought 20 years ago that it is possible to print components? The possibilities of additive production continue to grow and pose new challenges for BLANK regarding the investment casting process. "It is important to keep up with the times and test out innovations on the market," says the head of the Mould Construction Division at BLANK, "The creation of a tool is at the beginning of the manufacturing process of an investment casting part, and also here potential is already being exploited by the additive production methods. At the end of 2017 for example, the first 3D printer was purchased in the Mould Division making tools or tool parts based on synthetic resin. The printer is comparable to an inkjet printer, however, the print is done with liquid resins instead of ink and the components for the tool are built up in layers. Whether tool printing is suitable for an investment casting part depends on several factors, such as geometry, accuracy and batch size. FORMENBAU BLANK can print parts up to 250-250-200 mm.”

Beside the components for a tool, the printer can also be of great importance at other points of the investment casting process. For example, parts of fixtures can also be printed for subsequent machining processes. In addition, an appropriate device facilitates the subsequent testing process of the cast part in the measuring laboratory. The person responsible for 3D printing in mold making reports: "We like to use the printer for illustrative material. It's simply something different when you can hand over the later investment casting part to the customer and show him what it will look like one day. This creates mutual understanding and has often enabled design issues to be discussed and clarified in a vivid way." Furthermore, it is possible to verify the form and fit of the future component in the end application. However, the new technology also presented new challenges, especially at the beginning: "If a tool is printed, it is made of plastic," explains the head of the tool and mould shop. "If it is used in the subsequent process in an automatic spraying machine to produce the wax pieces, the tool heats up continuously. Heat dissipation is lower than with a fully milled aluminum tool due to the material. Therefore, suitable measures for cooling the tool must be implemented in order to achieve economical production.", he added. Additive manufacturing provides decisive advantages, such as increased flexibility and significantly faster availability. In addition, this manufacturing method saves time-consuming work steps and optimizes the "time to market". 3D printing is a worthwhile alternative for highly complex components in small batch sizes that must be available quickly and cost-efficiently.

•  Additive manufacturing