Rollamo Engineering

TOOLING

LOST FOAM PATTERN & FIXTURE DEVELOPMENT

Understanding the criticality and complexity of the component, Rollamo's engineering team devised a multi-slice lost foam casting methodology to eliminate core defects and maintain internal geometry.

6 SLICES

Cut casting into 6 cross-sectional slices for precise modeling

LOST FOAM MOLD

Engineered complex multi-part tooling for lost foam process

GLUING FIXTURES

Developed alignment fixtures to join foam patterns seamlessly

MACHINING

6-SIDED PRECISION REFERENCING

The casting required precision machining on all six sides, making accurate multi-axis referencing and specialized tool geometries critical to achieve repeatable tolerances.

2 SIDES

Machined individually with custom datum fixtures

4 SIDES ROTARY

Machined using rotary indexing / 4th axis machining

SPECIAL TOOLS

Custom cutting tools developed for internal features

150 OPERATIONS

Total synchronized operations per component

RESULT

DRAMATIC REDUCTION IN CYCLE TIME

Through multi-axis process consolidation and specialized cutting tools, Rollamo achieved extraordinary manufacturing throughput without compromising dimensional accuracy.

50%

Reduction in Original Cycle Time

35 min

Final Optimized Cycle Time