‹ Back to Columns

Casting Design Solution

Shannon Wetzel

One of the main goals of Casting Source, as a publication of the American Foundry Society, is to provide specifiers and engineers information on how casting processes can be cost effective and meet complex requirements. We want to answer the fundamental question, “Why casting?”
Our regular contributing columnist David Charbauski provides a nuts-and-bolts answer to that question in this issue on page 8. Not every part or application is a fit for casting, but for those that are, the process can give designers ultimate freedom to get the shape and properties they need.
This is illustrated in the case study on page 20, “Long Day’s Journey Into Right.” Inventor Flent Ballantyne had a great idea for roofwork fall prevention, but spent years looking for a way to manufacture it.  
Starting with a first prototype made from a steel rod, Ballantyne explored an I-beam made from sheet aluminum, sophisticated plastics, and sources all over the world, from Texas to China. 
Finally, Ballantyne arrived at a cast version and found a capable and willing casting supplier in Carley Foundry. His EVEOOK is lightweight but can stop at least 7,200 lbs. of free-falling force. It could save lives and prevent serious injuries.
It took Ballantyne—who had other businesses to run­—more than a decade to fulfill his objective. Hopefully, readers of this magazine can conclude earlier in their design process whether metalcasting is the most viable option.
Casting Source’s website, 
www.castingsource.com, has a full archive of articles on casting design and case studies that provide examples of other companies discovering the business case for a cast product.  Further, the online Casting Source Directory helps you connect with casting providers in North America for future partnerships. 
Finally, if you have a design success story of your own, we would love to hear it. Reach out to me at