This page contains a Flash digital edition of a book.
A


A passenger aircraft seat frame is a structural component uniquely


designed for each aircraft confi gura- tion. Typically, they are constructed from a single billet. But was there a better way to manufacture that could also reduce costs? Autodesk, a leader in 3-D design and engineering software, had been developing a diff erent way of design- ing using generative design software, which automates design options based on specifi c criteria such as weight and strength to perfect and speed up the design process. T e company’s research led to a unique lattice-like struc- ture, and they contacted Aristo Cast (Almont, Michigan), an investment caster with experience in prototyp-


ing and magnesium, to help carry out the design for an aerospace seat frame. T rough collaboration and sound casting principles, AristoCast delivered fi nal castings in four weeks that reduced weight by more than half compared to other lightweight frames on the market. Because of the benefi ts to the end-user and potential for casting growth in other applica- tions for lightweighting, the aerospace seat frame has been named this year’s Casting of the Year by AFS and Metal Casting Design & Purchasing magazine. Using the generatively designed


model, Autodesk sought to take out as much material as possible without aff ecting the strength requirements needed. T e result was a much lighter seat frame with material located only


were needed. T e new shape was a perfect fi t for investment casting. “T e casting design showcases the


ability to change lattice thicknesses to add strength where it is required,” noted one judge in the casting competition. “T is concept can be used to tie sections of a casting together where strength is not so critical to reduce weight.” Autodesk originally started devel- oping its generative design software for 3-D printing of direct-to-metal parts. But metal printing is con- strained by size, and the team began considering how to use the model for other manufacturing methods. Met- alcasting was a natural choice because additive technology can be used to make the patterns and tooling. To gain interest from aerospace and


May 2017 MODERN CASTING | 25


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64  |  Page 65  |  Page 66  |  Page 67  |  Page 68