Shell Mould Casting for Agro Farm Machinery — 35% Cost Reduction
An agro farm machinery OEM approached Amsol requesting investment casting for a set of agricultural machinery components. The components were critical functional parts — required to withstand abrasive soil, variable impact loads, and continuous field operation.
Customer Specified Investment Casting. Amsol Recommended Shell Mould. The Savings Were 35%.
An agro farm machinery OEM approached Amsol requesting investment casting for a set of agricultural machinery components. The components were critical functional parts — required to withstand abrasive soil, variable impact loads, and continuous field operation.
Amsol's engineering team reviewed the drawings and disagreed with the process selection. The components were medium-complexity geometry, the volumes were moderate, and the tolerance requirements did not demand the surface finish premium of investment casting. Investment casting would have worked — but at a 35% cost premium the customer did not need to pay.
Why Shell Mould Was the Right Answer — Not Investment Casting
The customer assumed investment casting was required for dimensional accuracy. Amsol's review showed shell mould achieves the same drawing tolerance at 35% lower cost for this geometry and volume.
| Parameter | Investment Casting (Specified) | Shell Mould (Amsol Recommendation) |
|---|---|---|
| Cost per part | High — 35% above shell mould | 35% lower ✓ |
| Surface finish as-cast | Ra 1.6 µm (over-specified) | Ra 3.2–6.3 µm (exactly required) ✓ |
| Tolerance grade | CT4–CT6 (tighter than needed) | CT5–CT7 (met all callouts) ✓ |
| Cycle time | Longer — ceramic shell 24–72 hrs | Faster — shell forms in 60–90 sec ✓ |
| Volume suitability | Better for low volume / high complexity | Ideal for medium-high volume ✓ |
What Changed — The Outcomes in Numbers
Every result below is documented. This is what Amsol's engineering-led approach delivered for this customer.