We are constantly are looking for ways to lower our customer’s costs while still supplying the same high quality components. This is exactly what happened when we converted previously fabricated components into single castings to improve efficiency and reduce cost. The products in question were tailgate components used in the mobile refuse collection industry. Our customer expressed their interest in converting manyfabrications involved in this assembly into castings to reduce costs. We successfully designed 11 castings that replaced previously fabricated components at a lower expense. In thecourse of this process, we realized that to ensure proper solidification of the castings, the geometry of the castings would not exactly match the geometry of the fabrications. We were not deterred, however, and successfully created 3D models and 2D machined drawings of the finished product. The customer then utilized the 3D models to make sure all clearances and dimensional tolerances would be acceptable on the final cast products, enabling them to provide the same function as the fabricated products. We cast the components and then worked them on our vertical turning lathes, horizontal machining centers, and gantry lathes. We manufactured the casting to tight tolerances of ±0.002”, finished them to a roughness average of 32, and welded them together on our burning tables. Go/No-go gauging was used for inspection of the tailgate,which was 35” long and 40” wide upon completion. We also provide FMEA analysis, but it was not called for in this particular project.We completely satisfied our customer’s specifications and requirements, fabricating 11 of these tailgate assemblies in only 45 days for delivery to Houston, TX. This is the kind of versatility and dedication we can bring to your machining project. ContactCAB Incorporated today to talk to our design and engineering staff.