NU - CAST, INC A Leader In Aluminum Investment Castings THE INVESTMENT CASTING TEAM PROVIDING FOR “REAL SOLUTIONS” THROUGH EXPERIENCE, UNDERSTANDING, QUALITY, FLEXIBILITY & INOVATION ENGINEERING, DESIGN & RAPID PROTOTYPING ALUMINUM INVESTMENT CASTINGS NU-CAST, INC. (NCI): Londonderry, N.H. 603-432-1600 PROTO ENGINEERING: Lowell, Ma. 978-446-0570 NU - CAST, INC NU - CAST, INC NU - CAST, INC NU - CAST, INC NU - CAST, INC PROTO ENGINEERING EXPERIENCE/BACKGROUND: ? 36 years in the design, development and management of ground based, airborne and spaceborne optical reconnaissance systems @ ITEK/LITTON. ? 15 years full time and 18 years part time (consulting, design and rapid prototyping) in the investment casting field @ UNI-CAST/NU-CAST. MAJOR SYSTEMS/PROGRAMS: ? Corona (secret satellite) declassified 1995. ? Classified reconnaissance systems (airborne/spaceborne). ? MOL (Manned Orbiting Lab). ? CIS (Compensating Imaging System) Maui ? Manager of major A/C modification (G111) and systems integration for recce platform including large optical windows and requiring FAA certification/STC’s. NASA RELATED PROGRAMS: ? Large Space Telescope (Hubble) proposal/study. ? Apollo Program (pan camera for moon). ? Viking Program (Mars Lander camera). ? 30 meter space based laser transmitter (proposal/study). ? Principal Investigator, SBIR Phase 1 & 11 (High Efficiency Monolithic Lightweight Cast Structure). PROTO ENGINEERING SERVICES: ? Review systems/components on the basis of function, design, producibility and cost. Discuss casting issues with proposed designs. Provide specific recommendations, alternate design approaches and supporting rationale. ? Systems/component design specializing in airborne & spaceborne applications. ? Investment casting design. ? Optical systems, components and their mounting. ? Structural systems and mechanical components. ? Electronic enclosures. ? Provide knowledge (basic principles) of the investment casting process and how to realize the maximum benefits of this versatile process based on current technology. ? Design to cost. Recommend options and provide direction for an efficient cost effective approach. ON SITE (CUSTOMER) OR @ PROTO ENGINEERING: PROVIDE SEMINARS ON THE INVESTMENT CASTING PROCESS AND INVESTMENT CASTING DESIGN (ALUMINUM): INVESTMENT CASTING DESIGN & ENGINEERING: PROTO ENGINEERING INVESTMENT CASTING DESIGN & ENGINEERING (CONT’D): ? View problems/issues through the eyes of the customer as well as the foundry, concentrating on part functional requirements for practical solutions. Note; the many years of airborne and aerospace design experience along with the association and actual foundry experience by Proto Engineering, provides for this unique opportunity. ? Provide for realistic tolerancing, dimensional set-up (datum’s/tooling points) and proper transitioning to machining (kinematic type restraints, tooling lugs, etc.). ? Determine those areas/features that should be cast and those that should be machined due to tolerancing or configuration limitations. ? Recommend design techniques that minimize distortion when machined and those processes recommended for long term casting stabilization (critical optical configurations). ? Provide casting design, supporting analysis (FEA/NASTRAN), detail drawings (casting & machining) and solid model (CAD) or variations as required. See the following for typical approach: ? Discuss/establish design requirements, goals and gather the necessary interface/environmental data via “SCD” or appropriate agreed upon format. ? Provide preliminary design/layout of proposed approach for customer evaluation and subsequent update and approval. Note; FEA/NASTRAN analysis would be provided at this time if required by customer. ? Provide detail casting and machining drawings (2D) on customer format per customer specifications and solid model (3D) as required of approved design PROTO ENGINEERING INVESTMENT CASTING DESIGN & ENGINEERING (CONT’D): ? Provide design/detail drawing (2D) and solid model (3D) conversion as required for the following: ? Provide engineering drawings per Y14.5M - 1982 or Y14.5M - 1994. ? Assist in material and specification selection: ? Recommend material specification, classification and method for determining mechanical properties, x-ray of designated areas (when required) and general processing notes based on system/component requirements. ? Discuss/define advantages/disadvantages. ? Dip brazing to casting. ? Sheet metal to casting. ? Weldment to casting. ? Machined part “hog out” to casting. ? Multi-piece assemblies (sheet metal or machined) to casting. ? Design/detail (2D & 3D) via CADKEY and or PRO E. ? Systems/part analysis (FEA) via NASTRAN). ? Provide the following: PROTO ENGINEERING RAPID PROTOTYPING (WOOD PROCESS): ? Rapid prototyping process for investment castings unique to Proto Engineering and Nu-Cast Inc Pattern fabrication is via A/C plywood (computer generated or machined assembled parts) as compared with the use of computer generated resins (SLA). This process has been used for over 35 years and currently provides additional flexibility in the use of investment castings for limited production or development runs. ? Advantages over the SLA type process: ? Design changes can be implemented at any time during pattern generation and even into the shell process in extreme situations. This process in general allows for changes after pattern review. ? Pattern/part size limited to foundry facility only (currently 80 inches in length @ Nu-Cast Inc). ? Solid model (CAD) not required (2D acceptable). ? Fillet radii and outside radii not required in CAD file. ? Minimal wall thickness .02/.03 available (requires engineering or foundry review). ? No pattern shrinkage to contend with allowing for greater pattern tolerance control, Proto Engineering Aerospace/Investment Casting Design and Rapid Prototyping Gordon H. Goodwin PROTO ENGINEERING NU - CAST, INC Wax Injection (Large Injection Tool Depicting Cores With Red Wax Pattern On Left) NU - CAST, INC Wax Assembly Shell Shell NU - CAST, INC Part Production Cycle - Investment Castings NU - CAST, INC Electronic Housing (Investment Casting) Electronic Housing (Investment Casting) NU - CAST, INC Optical Housing (Investment Casting) NU - CAST, INC Electronic Housings (Investment Castings) NU - CAST, INC Optical Housing (Investment Casting) Electronic Chassis (Investment Casting) NU - CAST, INC Missile Electronic Housing, Cover & Chassis (Investment Casting) NU - CAST, INC Electronic Housings (SLA”S) Electronic Housings (Investment Castings) NU - CAST, INC Gimbal & Housing (SLA’S Housings (SLA’S) NU - CAST, INC Housing & Covers, ATIRCM (SLA’S) Housing, Support, ATIRCM (SLA) NU - CAST, INC Housing Housing (Investment Casting & SLA) (Investment Casting & SLA) NU - CAST, INC SLA PATTERNS Thrust Deflector Housing TOP: THAAD Optical Sensor Housing BOTTOM: Pump Housing LEFT: Deflector, Investment Casting RIGHT: Deflector, SLA Pattern NU - CAST, INC FLIR Optical Housings, Inv. Casting (Casting Design/Engineering By Proto Engineering) TOW Optical Housing, Inv. Casting (Casting Design/Engineering/Conversion By Proto Engineering) Electronic Housings (Investment Castings) NU - CAST, INC Rail, A/C Missile Launcher Housing (Investment Casting) Rail, A/C Missile Launcher Housing (Investment Casting) NU - CAST, INC Optical Bench, “3D” Truss, Offner Relay Test, NASA/GSFC (SBIR II) Wood Prototype (Top), Investment Casting (Bottom) NU - CAST, INC J. Bowkett With SMEX ? Lite ,NASA/GSFC (Wood Prototype, Other Samples In Background) NU - CAST, INC DB - 110 Recce Roll Frame & Optical Bench (Wood Prototypes) NU - CAST, INC DB - 110 Roll Frame (Goodrich Recce System) (Investment Casting Designed By Proto Engineering) NU - CAST, INC DB - 110 Recce System, Goodrich Roll Frame & Optical Bench (Wood Prototypes ) NU - CAST, INC DB - 110 Recce System DB - 110 Recce System (Camera Assembly On Fixture) (Camera Assembly On Fixture) NU - CAST, INC Boeing 767 A/C Main Landing Gear Door Uplock Support (Cast Conversion) NOTE: Conversion Eliminated 27 Part Numbers Boeing 777 A/C Outboard Overhead Stow Ben End Frame (Cast Conversion) Boeing 767-40ER A/C Cockpit (Cast Conversion) NOTE: Conversion Reduced 296 Part Numbers To 53 (With 11 Casting Assemblies) & Cost By 50 %