Lightweight aluminum and magnesium castings are often used in the production of medical devices.   Many times these castings are used to house and protect critical components. Casting design needs to take into account structural, castability, and manufacturability considerations.   

The paper covers structural considerations with a focus on part geometry.  Then, castability considerations will be discussed – this will include a discussion of the impact of a casting processes on tolerance capability, draft, contraction, and geometry of gating/risering, fixturing, and finishes.  Lastly, manufacturability considerations will be reviewed.  Taking into account factors such as a manufacturer’s conveyor systems and pick and place operations when designing a casting often results in improved product quality and reduced assembly cost.  Practical considerations related to automated and semi-automated processes will be discussed. 

The focus of this paper is on reducing material usage, cost, and time-to-market.   Real life examples demonstrating design considerations and their impact on project outcomes will be presented.