Land Rover Rapid Casting and CNC Machined Gearbox
The client already had the 3D CAD data for the housings which we received and imported into our 3D CAD software Solid Works. With the short time frame required by the client, the most efficient manufacturing methods needed to be decided. With speed of manufacture and accuracy as the two main considerations. It was decided that the best method to use was to firstly SLS rapid prototype the gearbox housings. This SLS model could then be used to create a ceramic mould for the rapid investment casting process. Production of the aluminium casting followed at a subcontractor foundry. CNC machining in house of the high precision features completed the parts ready for assembly and test at the vehicle manufacturer.
Why Choose Thompson Precision
Latest CNC Technology
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Fast & Accurate
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High Precision Experts for 85 years
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Large Scale CNC Milling
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SLS Rapid Prototyping
For the first process of SLS rapid prototyping the 3D CAD data received from the client had to be modified with material added on in certain places that would need to be machined later. These modifications were all done in Solid Works,our 3D CAD software,and once finalised the SLS rapid prototype models were made.
These were then inspected with our CMM (co-ordinate measuring machine) to ensure the accuracy of the housings. From here ceramic moulds for each housing could be produced. These moulds were then used for the rapid investment casting process. The aluminium castings of the housings were then given to our CNC engineers where they used the 3D CAD data used to make the SLS models and the original CAD data from the client. Here they could import both sets of CAD into our CAM software Power Mill to work out the areas of the casting that needed machining. Then each casting was machined on our CNC machining centre to match the clients data, from here the finished castings were fully inspected with our CMM to make sure it met our clients quality requirements whilst meeting the delivery schedule.
Testimonials
Accuracy and Finish
- Machine shop special effects
Met our Deadlines
- F1 Team
Highly Recommend
- Cambridge Consultants
Demanding prototype components produced in days without fuss. Thanks for your help.
Great quality work
- Tasha Trigger
These guys helped me out on a time sensitive project. Very professional and responsive via email.
Highly Recommend
- Mekhalfia Group
Very helpful company, I highly recommend them. They helped our sister company Fiil e-motion with the best solution.
Speed Service
- Murali V
High speed service as stated.
Mace Group
- Mace Group
What impressed most was not only the quality and attention to detail, but also the professionalism, flexibility, and commitment shown by the team throughout the process.
Figure AI
- Figure AI
The parts you sent arrived in record time and they looked great.
Thorlabs
- Thorlabs
Many thanks to you and the team at Thompson for your support and assistance this year. We do appreciate the excellent job you have done. Would not hesitate to work with you again.
3P Innovation
- 3P Innovation
We carried out a trial order review on the parts you delivered and you have scored perfectly on the form! Really impressed with your work on this project for us, so thank you very much!
Bowyer Engineering
- Bowyer Engineering
Just a quick note to thank you for the big plate you manufactured for me. It all fitted perfectly, and it would have been a disaster for me if it hadn’t been correct or delivered late.
Get in Touch
Rapid Prototype Gallery
Large Scale Rapid Prototype
High Detail SLS Nylon
Large Rapid Prototype Parts
Large SLA with Chrome Plating
Complex Rapid Prototyping
Automotive Gearbox Rapid Prototype Parts
Case Studies
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Mechanical Prototyping of a Fishing Reel
The client for this case study had a new fishing reel concept that they wanted us to manufacturer so they could test it out before taking the design further.
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