Head design and casting cost? - Don Terrill's Speed-Talk
Head design and casting cost? - Don Terrill's Speed-Talk
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Designing, testing and developing engine castings is my everyday work.
If you want to make a low production head, you need to already have access to an efficient system or break-even is many years away for most projects.
Even high production stuff has a long ROI.
For someone that comes to individual service providers, the prices will be as listed below and the results will not be good
unless the whole chain is working together from beginning to end.
If you try to do this one step at a time, expect to fail.
1. Scan an existing casting and head gasket for reference data $300-$3,000
2. Measure a block for precise dimensions $300-$1,000
3. Model the head in CAD $1,000 - $30,000 (for a performance aftermarket head depending on complexity and optimization). Sound expensive? An OEM might spend $400,000.
Do not waste your time with someone that uses Solid Works for cylinder heads or manifolds, the limitations of the software will build compromises into the design.
Find someone with NX, CATIA or CREO that knows about foundry tooling design and casting to do quality work.
There is a huge difference between someone that thinks they can model a head and someone that can design a head that can be used to efficiently design foundry tooling.
A good head designer does CFD on the water jackets and ports.
4. Design/model the foundry tooling (patterns core boxes) $1,000 - $15,000 depends a lot on complexity and how well the head was designed for casting. If you take a short-cut and design a head without knowledge of foundry tooling design thinking that the "tooling guy will just change it" ; plan on spending more that the design cost and getting something different than what you wanted.
5. Tooling, it depends on how many castings you want to make.
The more you plan to make, the more you should spend as expensive tooling makes better parts for lower cost.
$3,000 for a printed sand mold to make one head.
$5,000 for a crude wood pattern for a simple head.
$30,000 for an ordinary performance after-market head in urethane
$50,000-$75,000 for hybrid urethane & aluminum tooling
Prototype casting 5 heads to section for examination and test $
Pattern modifications to fix issues, (cracks, shrinkage, warping, porosity, short fill etc) $1,000 - $10,000
6. Casting $200 - $2,000 depending on complexity, tooling, problems.
7. Machining fixtures design $1,000 - $
8. Machining fixtures $1,000 - $
9. CNC Programming $1,000 - $5,000
10. Special tooling, cutters etc. $500 - $10,000
11. Base machining $200 - $2,000 depending on complexity.
12. Leak testing $30
13. Valve job machining $100-$500
14. Dyno engine
15. Dyno testing
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