Cost control is the core of a company’s competitiveness. For fields like stainless steel investment casting, where the process is complex and material requirements are high, effectively reducing costs without sacrificing quality is a challenge every foundry must face. This article will share QD’s practices and achievements in reducing costs and increasing efficiency.
Cost Composition of Stainless Steel Investment Casting
The costs of stainless steel investment casting mainly include raw materials, mold making, labor, energy consumption, equipment depreciation and management expenses.
The following is a typical cost analysis table:
| Cost Item | Proportion | Description |
| Raw Materials | 40% – 50% | Including stainless steel ingots, auxiliary materials, etc. |
| Die Making and Maintenance | 15% – 20% | Wax patterns, shell molds, etc. |
| Labor Cost | 10% – 15% | Expenses for operators, inspectors, management personnel, etc. |
| Energy Consumption | 8% – 12% | Electricity, gas, water, etc. |
| Equipment Depreciation and Maintenance | 7% – 10% | Melting furnaces, wax injection machines, dewaxing equipment, etc. |
| Others | 5% – 8% | Quality management, environmental protection treatment, etc. |
As can be seen from the table, raw materials and molds are the main components of the cost.
QD’s Practices in Cost Management & Control
Refined Stainless Steel Scrap Recycling System
We have established a closed-loop waste management system that enables the classified collection, component analysis, and precise recycling of stainless steel scrap. This system uses spectral analysis to rapidly test recycled materials, ensuring their chemical composition meets standard requirements. After purification, the recycled materials are combined with new materials in a specific ratio.
This system is designed for widespread use in structural and decorative parts requiring less stringent mechanical properties.
Systematic Implementation Process:
- Establish waste material classification standards to achieve detailed classification at the source
- Introduce rapid component analysis equipment to monitor material quality in real time
- Develop an intelligent proportioning system to automatically calculate the optimal feed ratio based on product requirements
- Establish a material traceability system to ensure traceability of materials for each batch of products
Wax Model Life Extension Technology
Through material modification and process optimization, we have successfully increased the average use of wax models from the industry standard of 5-6 times to 10-12 times.
We use polymer-modified wax and optimize the recycling and purification process. We also maintain a wax model usage record.
Technological Innovations:
- Development of specialized wax additives to improve wax performance
- Design of a multi-stage filtration system to increase the purity of recycled wax
- Implementing a wax pattern usage monitoring system to ensure optimal efficiency
- Establishment of a wax pattern performance degradation model to predict the optimal replacement time
This technology significantly reduces mold costs and ensures production continuity.
Intelligent Production System Integration
QD invested millions in an automated production line, automating key processes such as wax injection, shell making, and dewaxing. Advanced equipment such as a robotic slurry dipping system and automated sanding equipment were also introduced, reducing reliance on manpower.
Intelligent Upgrade Path:
- Implement equipment automation transformation in phases, prioritizing labor-intensive processes.
- Develop a Manufacturing Execution System (MES). Enable real-time equipment data collection.
- Establish a process parameter database. Optimize production process windows.
- Implement a predictive maintenance system. Improve overall equipment efficiency.
The intelligent production system has increased QD’s production efficiency by over 30%, making delivery cycles more stable and providing customers with reliable supply chain support.
Precision Control Technology for Mold Shell Materials
Leveraging a mold shell material performance database, we achieve precise control of mold shell proportions. We have introduced an online monitoring system to monitor the mold shell drying process in real time.
Technical Breakthroughs:
- Development of a mold shell material performance prediction model
- Implementation of an automated proportioning control system to reduce human error
- Establishment of a mold shell drying process monitoring system
- Development of a rapid detection method to ensure mold shell quality
This technology has reduced our mold shell cracking rate by over 50%, significantly improving the surface quality of castings.
Process Parameter Optimization and Standardization
We also established a comprehensive process parameter database. We used big data analysis to identify optimal process windows and implemented standardized operations.
Standardization Construction:
- Establish a product-process matching database
- Develop a process parameter optimization algorithm
- Implement standardized operating procedures
- Establish a process anomaly warning system
Systematized Energy Management System
QD also implements comprehensive energy management, taking multiple measures, including equipment upgrades, process optimization, and operational management. An energy monitoring platform has been established to monitor energy consumption at all stages in real time.
Energy-saving measures:
- Recovering waste heat from smelting furnaces
- Implementing energy-saving equipment upgrades
- Optimizing production plans and reducing equipment idling
- Establishing an energy consumption assessment system
This significantly reduces energy costs and carbon emissions, providing customers with more environmentally friendly casting products.
FAQ
1. What are the main costs of stainless steel investment casting?
Raw materials and mold making account for over 60% of the total cost. This is a key area for cost control.
2. Does scrap recycling affect casting quality?
No. As long as it undergoes rigorous component testing and purification, recycled material can be used for less demanding castings or, after adjustment, for standard parts.
3. Is investing in automated equipment worthwhile?
Yes. In the long term, automated equipment can significantly improve production efficiency, consistency, and safety, while reducing reliance on manual labor.
4. Why is it important to precisely control the mold shell material ratio?
Mold shell quality is directly related to the surface accuracy and defect rate of the casting. Accurate ratios can reduce problems such as cracking and deformation, thereby improving the yield rate.
5. Does QD Casting sacrifice quality in its pursuit of cost control?
Absolutely not. QD guarantees it will not. We always adhere to the principle of “quality first.” All cost-reduction measures are implemented under the premise of ensuring product quality.
6. How can customers benefit from these cost reductions?
QD will pass on the cost reduction benefits to customers through optimized quotes, improved delivery stability, and more competitive pricing.