As a Product Manufacturing Intern at Signify Canada, I was tasked with completely redesigning the sand casting tooling for one of the luminaire hanging brackets.
I used the original part (from damaged tooling) given to me as a dimensional reference. The design was CADed using SolidWorks. Draft angles were added to all the surfaces of the part touching the core to allow for easier opening of the mold. Draft analysis was performed for better understanding of all the draft angles.
The redesigned part was 3D printed in a 1:1 scale and compared physically with the actual part. The 3D printed part was tested in a 3-axis CNC machine Jig for dimensional accuracy analysis.
