Carrera Casted Cooling Fans, Now Available.

Discussion of 4-Cam Type 547 engines (and all the Fuhrmann racing variants) and cars that powered them.
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Ibrahim Kuzu
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Carrera Casted Cooling Fans, Now Available.

#1 Post by Ibrahim Kuzu »

Not for Concourse Engines ,
For Racers, now we are Casting 3D print Carrera 2 liter or 1500/1600 cc Engine Fans
Engineering analysis done at 20,000rpm.Fan blades are 2mm thick and 2 liter fan one Lb. lighter than original manufactured one.
And 1500/1600 cc one very close to original factory weight.
If Interested, Please call or email Bob Garretson.
4 Cam Cooling
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DaveErickson
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Re: Carrera Casted Cooling Fans, Now Available.

#2 Post by DaveErickson »

Ibrahim Kuzu wrote: Sat Aug 27, 2022 2:33 pm now we are Casting 3D print Carrera 2 liter or 1500/1600 cc Engine Fans
Hi Ibrahim, just interested in the process. Is the fan generated by 3D print used to make sand castings, or what?

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Ibrahim Kuzu
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Re: Carrera Casted Cooling Fans, Now Available.

#3 Post by Ibrahim Kuzu »

Hi Dave,
It is a 3D sand print ,than material Poured in ...One pattern one part ..If you do bad pouring (material temperature, Weather temperature, how fast you are going etc) all have effect on the end result...Our yield is around 4/1 meaning 4 good pour one bad one goes back to fire...
Due to very critical special part. ( Casting 2mm fan blades not every ones cake to eat....) .Than We machine the needed surfaces to the factory specs.

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Joris Koning
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Re: Carrera Casted Cooling Fans, Now Available.

#4 Post by Joris Koning »

Very cool Ibrahim, thanks for sharing!
'56 Coupe
'57 Coupe
'59 Cab 
'60 Coupe

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Ibrahim Kuzu
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Re: Carrera Casted Cooling Fans, Now Available.

#5 Post by Ibrahim Kuzu »

Thank you Joris,
Happy to be in the crowd of the special guys like, Mike Smith,Bob Garretson,Jacques Lefriant and others taking their time to make these non-existing Carrera parts
to keep the 356 Carrera faith going .

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Martin Benade
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Re: Carrera Casted Cooling Fans, Now Available.

#6 Post by Martin Benade »

It’s lost wax casting? Your rejection rate sounds good to me.
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Ibrahim Kuzu
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Re: Carrera Casted Cooling Fans, Now Available.

#7 Post by Ibrahim Kuzu »

Hi Martin ,
Not wax casting.3D sand print Core Pattern .Wax casting also can be used in the choice ..But ours is Sand Print cores .

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Re: Carrera Casted Cooling Fans, Now Available.

#8 Post by Jim Wayman »

There is a 3D print material that is a plastic, but behaves like wax when hot metal is poured into the mold. Is that what you are using Ibrahim?
Jim Wayman

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Ibrahim Kuzu
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Re: Carrera Casted Cooling Fans, Now Available.

#9 Post by Ibrahim Kuzu »

Hi Jim,
We are not using Plastic.
It is Sand Core.
Please call me if you need more details.
IK

Jim Wayman
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Re: Carrera Casted Cooling Fans, Now Available.

#10 Post by Jim Wayman »

Ibrahim

Maybe I wasn't clear. There is a material that you 3D print that is plastic. It is then placed in a sand cast mold, the metal is poured into the mold and the 3D printed plastic part melts just like wax would.
Jim Wayman

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Martin Benade
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Re: Carrera Casted Cooling Fans, Now Available.

#11 Post by Martin Benade »

That is essentially a lost wax method, but this is quite different. Apparently the sand is printed into a mold shape leaving a very accurate cavity to pour the aluminum into. It’s one of those modern technologies that sounds nearly impossible but it works and is used commercially.
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Ibrahim Kuzu
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Re: Carrera Casted Cooling Fans, Now Available.

#12 Post by Ibrahim Kuzu »

Hi Jim,
Just like Martin explained.
Thanks Martin...
IK

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Martin Benade
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Re: Carrera Casted Cooling Fans, Now Available.

#13 Post by Martin Benade »

I’m an expert now after reading various things from Google.
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DaveErickson
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Re: Carrera Casted Cooling Fans, Now Available.

#14 Post by DaveErickson »

Ibrahim, one point of clarification: does the 3d printing produce the pattern, which then is used to make the mold, and removed? Or does the 3d printing generate the mold directly? If the latter, then I think that implies the 3d printer is generating each grain of sand and it is also generating the binder to hold the grains together... Is the sand traditional silica sand or something else? Any way you look at it its pretty remarkable.

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PaulLima
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Re: Carrera Casted Cooling Fans, Now Available.

#15 Post by PaulLima »

I found this, which might help explain the process: https://www.humtown.com/3d-printed-sand-cores-molds

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