Ductile Iron Value Design and Prototype

Problem: A U.S. based valve manufacturer contacted Carson Castings with an RFQ for a new iron casting valve design they wanted to test for production.

The design would require extensive testing during the prototype stage and there would be a high likelihood that the iron casting would need to be modified prior to production.

The customer wanted to reduce costs on production tooling (due to the high chance of modifications being needed) and requested prototype tooling instead.

Solution: Carson Castings reviewed the design and discussed it with the client. During discussions it was determined that the coring of the iron castings could possibly change, but that the design of the exterior features were frozen.

Carson Castings proposed that instead of full prototype tooling, hybrid tools would reduce costs and increase future efficiencies. The patterns for the exterior features of the casting were produced as production ready tools; the cores were produced using 3-D sand printed molds (which require no hard tooling).

The cost to tool the jobs was similar to prototype tooling, but a savings of over 50% was realized when the jobs moved to production.


Conveyor Component 4lbs


Crankshaft 3lbs


Gear Housing 15lbs


Handel 2lbs


Link Pin 4lbs


Pillow Block 6lbs


Piston Cover 2lbs


Shaft and Hub Assembly 9lbs


Shift Fork 1lbs

If you require the same casting expertise at a competitive cost, please contact us today. Even though we use the latest technology to create our products, we believe some aspects of doing business never go out of style. At Carson Castings, we pride ourselves on industry values you would expect such as being responsive and ethical. We are optimistic about the future of the industry and are committed to it for the long haul.

The bottom line is that you can trust Carson Castings we know the dutile iron industry inside and out and we value you as a customer.

Sixty years of experience has netted millions of dollars of savings to our clients. Call us today at 844-722-7846, or request more information HERE.