Krugerrand
Meow
Just curious, how long would a "copy" of an existing die take, with minimal "tweaks" - weeks or several months? Is there some chokepoint that slows down the process - such as foundry capacity for high quality casts, or availability of CNC machines?
Also, how much extra time would "new" dies take typically - a few months on top, used mostly as human time - or are there material or machine dependencies as well? Very interesting topic!
Months and months for copies. Body sides are the most difficult to make and that time frame is yearish for a brand new set.
Just making the castings alone is about 5 weeks long time frame.
Every stage will be validated before going to the next. First they have to make Styrofoam forms that are digitally scanned (after feasibility checks and others from the designs). That’s at least a week ON TOP OF the 5 weeks for a full die set. There will be multiple forms for each die.
Then the Styrofoam forms are put in boxes and the forms are packed with sand. The packing process alone takes like a week and a halfish.
Then they pump in the molten casting material, the Styrofoam melts. Takes a day or so.
Then it takes a week and a half+ for the castings to cool. Not a typo. The castings can’t cool too quickly or they are junk-will be brittle or too soft. So they let them cool a bit, then open the boxes and let them cool a bit, then take away a bit of sand and let them cool a bit, then take away more sand, etc...
Then when the castings are cooled they have to cut off the extra bits; ie. pipes in and pipes out. Then the castings have to be digitally scanned and verified again.
The castings will have ‘over cast’ so next they go in a CNC machine to be ‘rough’ machined. Then there they will be ‘fine’ machining. Rough machining is a dayS long process, fine machining is much long. A single piece of cast can take 100+ hours to fine machine. Times that by multiple pieces of cast PER die.
Then everything has to digitally scanned again.
Then surfaces have to be heat treated. Then more scanning and fine machining because heat treating can cause distortions. Then more digital scanning and and and.
At certain stages, you can speed up the build process by throwing bodies at it, but a lot of the stages take the time they take and there’s no way to make it go faster without ruining the die/part of the die and then you get to start all over.
So, yeah. Months and months. And then when the dies are done, you’re looking at weeks to months to trial them and bring them up to optimization.
Copies save you time at the beginning during simulations and feasibility studies and the like, and should save time at the end during trials and getting the dies to run rate.