THE CHALLENGE
FROM TWO PARTS TO ONEThe impeller was originally manufactured as two separate parts — the fins and the top — which were glued together to deliver the final component.
The casting could not be manufactured as a single component because of issues in the die resulting in severe undercuts.
Rollamo's objective: manufacture the impeller as a single seamless component and eliminate the failure-prone glue line entirely.
Fins + Top
Original Design
Rollamo Solution
MANUFACTURING SOLUTION
WATER-SOLUBLE UREA CORE TECHNOLOGYFirst, a 3D model was recreated by measuring profile points from a physical cross-section cut.
To eliminate die undercuts, Rollamo developed an internal core using UREA. The material withstood hot casting wax and dissolved cleanly in water, allowing single-piece casting.
Profile recreated from measured cross-section points
Overcomes complex die undercut constraints
Withstands wax temperatures & dissolves in water
Internal cell core successfully cast as a single unit
CUSTOMER BENEFIT
SUBSTANTIAL HYDRODYNAMIC IMPROVEMENTThe elimination of the internal glue seam and the smooth surface profile delivered by Rollamo's single-piece casting technology significantly increased hydraulic flow performance.
Smoother internal fluid dynamics and complete elimination of glue joint turbulence
PROJECT GALLERY
COMPONENTS & TOOLING GALLERY
Single-Piece Impeller Casting
Complex Internal Curved Fins
Precision Machined Top Face
