This project was developed for an Australian customer in the automotive modification market. The customer had previously developed a similar product in cast iron sand casting, and this order was for a new aluminum casting version.
The parts were made from A356-T6 aluminum alloy and produced by shell mold casting. The full set included four matching casting components:
DANA 44 differential housing
DANA 44 differential hat
DANA 44 axle housing
DANA 44 bearing cap
Each set included one differential housing, one differential hat, one axle housing, and two bearing caps. Because the bearing caps are used in pairs, the cap quantity was double the quantity of the other three parts.
Casting Process Selection
For this aluminum casting project, we discussed two production options with the customer: shell mold casting and gravity casting.
Shell mold casting required a lower initial tooling investment, but the casting surface was not as fine as gravity casting. Gravity casting could achieve a better surface finish, but the upfront tooling cost was higher.
After comparing the tooling cost, surface requirement, order quantity, and project budget, the customer selected shell mold casting. This was a practical choice for the first aluminum casting development because the initial quantity was not very large.
Drawing Revision and Mold Modification
During the project, the large differential housing drawing was revised more than once. The customer updated the casting clearance, core structure, and mounting area according to their assembly requirements.
We worked with the customer to review the updated drawings and modified the mold accordingly. The housing mold was adjusted twice during development. These changes helped make sure the final castings matched the customer’s latest design and assembly needs.
For custom casting projects, drawing updates and mold revisions are common during the development stage. Our role was to support the customer with drawing review, mold modification, sample checking, and production follow-up.
Casting Production and Inspection
The parts were produced by shell mold casting. During production, the shell molds and casting patterns were prepared according to the approved drawings. After pouring, the raw aluminum castings were removed from the mold, then trimmed, cleaned, and checked.
The project included several different casting shapes, including the large differential housing, the differential hat, the axle housing, and the bearing caps. We also checked the individual part weights during production to help confirm the casting condition and packing arrangement.
The finished castings were checked together with the drawings before shipment.
Order Quantity and Delivery Arrangement
The order included:
30 pcs of DANA 44 differential housing
30 pcs of DANA 44 differential hat
30 pcs of DANA 44 axle housing
60 pcs of DANA 44 bearing caps
The customer needed some parts urgently for use. To support their schedule, we arranged 10 sets by air shipment first. The remaining quantity was arranged by sea shipment after production was completed.
This delivery arrangement helped the customer receive the urgent parts quickly while keeping the remaining shipment more cost-effective.
Packing and Shipment
The aluminum castings were packed with protective wrapping to reduce damage during transportation. The air shipment parts were packed separately for faster delivery, while the remaining sea shipment goods were packed in wooden crates.
Because the products are casting parts with different shapes and weights, we arranged the packing according to the part structure and shipment method.
Project Summary
This project shows our ability to support custom aluminum casting projects from drawing review and process selection to mold modification, shell mold casting production, inspection, packing, and flexible shipment arrangement.
For automotive modification components, differential housing castings, bearing caps, or other custom aluminum casting parts, we can manufacture according to customer drawings, samples, or application requirements.
Need Custom Aluminum Casting Parts?
If you need custom aluminum casting parts, automotive casting components, differential housings, bearing caps, or other aluminum alloy castings, we can help review your drawings and recommend a suitable casting process.
We can support shell mold casting, gravity casting, mold development, sample confirmation, production, inspection, packing, air shipment, and sea shipment for your project.
