A new casting placement technology has been introduced at the KAMAZ PJSC foundry, which has made it possible to increase their number in the mold and reduce the cost of production by 18–25%. Transferring more than 30 items to the new technology can create savings of up to 150 million rubles per year.
The key change is the vertical arrangement of castings in the mold. If previously up to 8–10 products were placed in one mold, now up to 60. This has dramatically increased productivity without expanding production.
The technology was pre-tested using 3D modeling, including casting and crystallization processes. This made it possible to identify errors at the design stage and reduce the time to implementation.
Additionally, 3D printing of cores was used, which form the internal geometry of parts. This approach simplified the development of the technology and reduced the cost of launching new items.
The new scheme is already used for castings weighing 1–5 kg, including fuel system parts. At the same time, it was possible to reduce defects and increase the accuracy of products.