Casting a Racecar Cylinder Head - Complete Process

In this video, we are showing you how do we manufacture a race car engine.
It was cast in 3D printed sand core, GOM, and CT scanned afterward.
Subscribe if you want to see more.
Amazing metal casting process.
Metal casting, Sand casting, Aluminum casting.

[@caseystyer2996]

This kind of work would be my dream job! No words can describe how excited and happy I would be showing up early Monday morning.

[@castingdesign1140]

Don't give up, go and get a job like that!😀

[@waqasmughal728]

@@castingdesign1140 l

[@waqasmughal728]

P pp

[@waqasmughal728]

Ok

[@waqasmughal728]

Pp

[@istvannyitray8867]

Jó bonyolult öntőminta! Szép munka!

[@igorsilvademorais7967]

Video mais completo sobre fundição do youtube. Congratulations 👏

[@HEMIcorporation]

This is so badass

[@nadazair8034]

Good job, i would've loved to see how they made the mould in Sand also

[@RHBTurbochargers]

3D printed most likely

[@OuTGoD]

3D printed

[@mutesajohnmark7260]

I love to learn this work

[@Aryan_Divyanshu_000]

Beautiful

[@marcadominguez]

Dope!

[@thewrencherz28racer92]

Nice. Can a pushrod hemispherical cast iron variant be made for a GM 3800 V6 with 2 plugs and valves per cylinder?

[@Sinarglondong]

Very good ❤❤❤

[@dekonfrost7]

I jave a job like this coming up. Gonna be fun. Your aluminum looked reallly good. Old honda heads for feedstock and vacuum degassing?

[@letcikigor]

Super👍

[@tamashernek7930]

Jo lett

[@watahyahknow]

wouldve loved to see how they made the more intricate sandmoulds , like the one for the coolant passages and the ports

[@castingdesign1140]

It was 3D printed, with a sandcore printer, I’m planning to make a video that cover’s this process.

[@castingdesign1140]

@@longhorn261 Thank you for the sub. I'm working on several casting videos with 3D printed pattern, also investment casting, so stay tuned.

[@alfatih8207]

@@castingdesign1140 Come please my job survey mining nickel and gold..investasion come

[@paradiselost9946]

the way that simulation on the fill worked, and how it actually did work with the slag all coming up in the final central riser... iunno if this was a middle finger to every pattern maker since the bronze age, or if it was a tribute... that was magic. at first im like... wtf is that coruscation? oh. tis the nasties all forced up and out...

[@ovalwingnut]

I'll take a dozen!

[@lawyerexperienced1442]

Круто сварено!!!!

[@bsk9911]

👍👍👍

[@lionelhaslam1979]

The skill is in the pattern making.Making sand cores is just filling boxes with sand then stacking them in the correct sequence.

[@castingdesign1140]

Well, someone have to design and make the patterns so it can be filled correctly.

[@censoredeveryday3320]

What software program was used for the fluid simulation at 0:59 ? Very cool. Thanks for a great video.

[@mctravel9662]

❤️️❤️️❤️️❤️️

[@cheetah.motors]

Great video, what is the name of the software ?

[@sengwesetogile6054]

What brand of furnace is that and how much does it cost? Can it also melt steel?

[@user-iw7yg4vx7i]

Круто

[@wiktorhogberg1646]

Very good video. But I wonder, do you have to take into consideration the thermal properties of aluminum when casting? I have been wanting to design and cast aluminum heads for racing applications for some time now but I don't know how to work with aluminum really.

[@newagetemplar6100]

Generally aluminium shrinks by 4% so when designing the patterns everything has to be 4% bigger in all directions. Then allow for machining, so faces that will be machined generally will have about 6mm added to them . Also it’s quite hard to centralise the casting when machining so on quite a long part like a cylinder head datum’s have to be checked. . What few people realise is that core plugs on bocks and cylinder heads are not there to stop the block cracking in a frost . They are there to support the cores ( cores for the cavities / water jackets ) . These can be clearly seen in the video. Quite hard to spot or understand if your not used to working in reverse/ negative. These are sand cast heads or old school ideal for small / medium batches . On some more modern engines they use pressure/ vacuum casting techniques usually injecting alloy from a large reservoir below and either forcing the material up and use a vacuum to get rid of the gasses . This improves quality and reduces chilling . Also on large batch production they will have a machine making the cores and a conveyor system to feed an automatic casting machine .

[@chumbeque4561]

​@@newagetemplar6100 sir, where did you acquired that amazing knowledge?

[@newagetemplar6100]

@@chumbeque4561 hi , just through a lifetimes worth of engineering, I had a very good friend who had been a pattern maker all his life and used to go down at night to his workshop. All hand done using old school techniques , sand boxes , contraction rates / shrinkage etc etc . Then I had my own castings made for WRC alloy uprights and machined them myself. This also ran along side my fibreglassing skills that I had leaned previously. I am now building a BMW E36 GTR race car with all composite panels and alloy uprights . I’ve been very luck in that respect as YT wasn’t around in the early 90’s . Fortunately now there is a vast amount on YT for people not as fortunate as myself . Many thanks for your kind comment. 😇🇬🇧

[@PhaseFabrication]

@@newagetemplar6100 In the case of pressure/vacuum casting would the part still shrink ~4% or does it maintain the dimension after cooling? Similarly, would a tall sprue/feeder supply enough head pressure to decrease the shrinkage as it cools? also would pre-heating the sand mold have any affect on shrink rates if it is allowed to cool slower?

[@paradiselost9946]

@@PhaseFabrication the shrink rate is a constant, thermal characteristic of the alloy. i have three rulers that are not allowed to be mixed up. brass, iron, aluminium. theyre precalibrated patternmakers rulers with the offset already applied. doesnt matter how its done, aluminium always shrinks a certain amount as it cools from a certain temperature.

[@AlekseyCamodelkin]

👍

[@nightcall2121]

🙏...👍

[@user-gk1iy8hb6h]

What tools are needed to make something like this

[@automan1223]

what would a head half this size complete to casting minus CNC finish work cost for a custom design based on an existing engine ?

[@trumanhw]

music wasn't great but the video was appreciated.

[@castingdesign1140]

I appreciate your comment.

[@vincenzo_1452]

How much does it cost??? Kinda curious.

[@carvior]

Con este método se podria fabrica el block motor de una motocicleta, que alumio usan me pregunto?

[@Doggiechafu]

whats the software for the simulation?

[@shantisadan8888]

Won't there be sand trapped in cooling jackets ?

[@DarmoNandar]

What sand is that? Ordinary sand?

[@JuanHernandez-mq2go]

Time to try this at home

[@_Wai_Wai_]

good way to recycle aluminum cans.

[@castingdesign1140]

Don’t try this at home

[@csaszino1]

Made in Hungary. :)

[@pkmechanics]

A1

[@AxelP33]

Hello, are the 2 dark grey parts made using 3d printed sand mold/cores ?

[@castingdesign1140]

Hello, Yes they’re made with an ExOne printer.

[@karnchan2589]

@@castingdesign1140 excuse me ExOne printer How much does it cost? ... Thank you...

[@castingdesign1140]

@@karnchan2589 we don’t own the printer we just ordered the prints but I believe it’s several hundreds of thousands of dollars

[@AxelP33]

@@castingdesign1140 cool, i believe this uses resin bonded sand ? Do you sell core/molds made on order or you only offer casting process ? I would like to cast a head my self , this 3d print technology would save quite a hassle with draft requirments 😄😄

[@robrob9050]

What's price for prints ?

[@billwelter4101]

Looks like the sand molds made by 3D printing

[@weiaungweiaung]

ok👍👍👍

[@tireballastserviceofflorid7771]

Wow. So how much would this cost? Would have to be off the charts.

[@SomeTechGuy666]

Way, way cheaper than machining billet.

[@tireballastserviceofflorid7771]

@SomeTechGuy666 Maybe. Once a program is dialed in CNC is very efficient and fast. Once the chips are weighed and sold that is.

[@Filholh]

Would you do a single cilinder head for the Honda XL250R 1983?

[@castingdesign1140]

We made cylinder heads similar to this for oldtimer motorbikes, I think it's possible but I need the design or a part that I can use to make the design.

[@Filholh]

@@castingdesign1140 Your work is awesome. Where do you do your work?

[@caneripek2349]

Hey! Sorry for late comment. Which program do you using for design to parts?

[@krisztianhernek685]

We use NX for product abd tool design. Custmer's model was Creo

[@caneripek2349]

@@krisztianhernek685 thank you so much!

[@randomvids3821]

​@@krisztianhernek685, is this your factory?

[@nhragold1922]

What race car is running those tiny valves, and ports!?

[@castingdesign1140]

It’s a special built Lada it will be a rally car.

[@superkas]

Maybe the valve lift intentionally to be built higher than my grade

[@nhragold1922]

@Casting Design ohhhh. Sorry I'm use to drag racing stuff. We run big stuff

[@user-si7cx5pc4s]

Собери Двигатель полностью и запусти его с это деталью!

[@alcyonegunantara7970]

Where u guys from?im interest with r product

[@krisztianhernek685]

Hi. We are in Hungary. In Europe.

[@zip7806]

What State?

[@upgfunny6488]

I want to learn to make a real car engine plz can you teact from begining wit every process

[@kensmechanicalaffair]

Lol

[@K-Effect]

Make them out of half-inch plate aluminum or steel

[@Matt44magnum44]

Cast a hemi head for sbc or ls

[@sengwesetogile6054]

Does it matter what aluminum you use for this?could i use melted soda cans?

[@castingdesign1140]

You could be able cast from melted soda cans but that would be probably full with porosity. We use customer defined aluminium alloy.

[@jamalabdulnasir2715]

what is the alloy that you used ?

[@krisztianhernek685]

AlSi10Mg0,3

[@portofino6790]

What application is used in 0:55 to simulate flow?

[@BusterChestnuts]

Magmasoft is a good casting sim software

[@mtrps_]

came here from b2b

[@_sdverse]

You should name the process then it will be more clear to understand

[@kaijuuARH]

Where’s the 2nd part of the video?

[@castingdesign1140]

There is no 2nd part yet, it’s under production.

[@ellgwapo.1754]

Very nice! & Donth' Cut too' much.

[@raheeskhan8772]

Rahees

[@olfoundryman8418]

Disappointing to see that with all the design freedom that 3d sand printing allows that such poor sprue and basin designs have been used, and at the very least I would have thought that in mould filters would have been incorporated... Martin

[@fusestation2839]

why not add two more pistons and custom CNC cam 😆🚬

[@castingdesign1140]

We didn't designed the part but I believe there is a good reason for why is it like this.

[@balintszolga6131]

Hello

[@castingdesign1140]

Hello

[@herbertpaerera8825]

@@castingdesign1140 c

[@kompresorairteknologi]

Airman screw compressor : kzbin.info/www/bejne/a5WzlZqgjb9laac

[@user-ib1ni5uj7u]

oky y

[@Chez8922-kf6cy]

The music is obnoxious and loud. It's noise pollution.

[@user-uc7yr7ql3e]

👍