The Challenge: Too Many Parts, Too Many Problems
A Midwest OEM came to Precision Enterprises with a familiar issue: a multi-piece welded assembly that had become a bottleneck.
Their existing component required:
- Multiple fabricated parts
- Precision welding and rework
- Secondary machining operations
- Frequent quality inconsistencies
Each unit introduced variability. Distortion from welding caused fit-up issues. Labor costs were climbing. Lead times were unpredictable.
What started as a workable design had become expensive, slow, and difficult to scale.
The Opportunity: Consolidation Through Sand Casting
Instead of optimizing the existing weldment, the engineering team at Precision Enterprises took a different approach:
Eliminate the assembly altogether.
By redesigning the component as a single-piece sand casting, they were able to:
- Combine multiple parts into one cohesive structure
- Engineer in strength where needed
- Remove weld distortion entirely
- Design for repeatability and precision
Our Process:
We start with our customer’s weldment from which we create a master pattern, and then use this pattern to pour sample aluminum sand castings for customer approval. After final approval, we schedule the final tool for production.
Before vs. After: From Fabrication to Aluminum Sand Casting
Typical Multi-Piece Weldment to an Aluminum sand casting
Problems Solved:
Typical possible weld defects distortion shown below has been eliminated!
Below is a more complex weldment that Precision Enterprises is currently working to convert to an aluminum sand casting. This conversion will take a series of core boxes to make the perfect completion of a complex weldment to a more cosmetic part for our customer.
The Solution: Smarter Design, Better Manufacturing
Working collaboratively with the customer, Precision Enterprises:
- Redesigned the geometry for castability and strength
- Incorporated uniform wall thickness to reduce defects
- Built in machining allowances only where needed
- Added the customer’s logo directly into the casting where applicable
The result was a replacement part, plus a better-engineered component.
The Results: Measurable Gains Across the Board
Cost Savings
- Eliminated welding labor and fixture costs
- Reduced machining time significantly
- Lower overall production cost per unit
Time Savings
- Shorter production cycles
- Fewer process steps
- Improved delivery consistency
Quality & Consistency
- No weld distortion
- Improved dimensional stability
- Tighter, repeatable tolerances
Assembly Advantages
- Single-piece design simplified installation
- Reduced part count lowered failure points
- Easier integration into the final product
Added Value: Branding Built Right In
One unique advantage of sand casting is the ability to integrate features directly into the part.
In this case, Precision Enterprises cast the customer’s logo directly into the component, delivering:
- Permanent branding
- A more professional finished product
- Zero added cost for marking or labeling
Why Sand Casting Was the Right Choice
Sand casting provided the flexibility to:
- Produce complex geometry in a single piece
- Maintain strength while reducing weight
- Support both low and mid-volume production economically
For this customer, it transformed a problematic fabrication into a scalable, high-quality solution.
The Bigger Takeaway
If you’re relying on welded assemblies, you may be carrying unnecessary:
- Cost
- Lead time
- Quality risk
Re-engineering into a casting just might be the manufacturing change and the competitive advantage you’ve been looking for!
Ready to Simplify Your Parts?
With 80 years of experience in the foundry business, Precision Enterprises specializes in helping manufacturers:
- Consolidate components
- Reduce production costs
- Improve product performance
If you have a complex weldment, there’s a good chance it can be done better as a casting. Reach out today.
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