Coldplate Manifold
ProductionA413ComplexAt riskcoldplate-manifold
Where this job stands
Pressure tight at 2.5 bar is the acceptance gate. A413 chosen over A380 for exactly this.
Commercial
- Tooling cost
- $6,595
- Committed volume
- 2,000 pcs
- Quote
- Q-2602-HALC-01Geometry
- Quoted per piece
- $15.25
- Break-even against CNC
- 44 pcs
- Rework buffer
- Included in quote
Geometry
- Solid volume
- 174,200 mm3
- Intersection volume
- 246,300 mm3
- Bounding box
- 186 x 120 x 28 mm
- Casting weight
- 0.655 kg
- Parts per mold
- 16recomputed 16
- STEP file
- uploads/halcyon/coldplate-manifold-r6.step
Casting trials
3Production runs
396.5% yield
| Date | Ordered | Delivered | Yield | $/pc | Margin | Batch |
|---|---|---|---|---|---|---|
| Apr 14 | 600 | 561 | 93.5% | $17.69 | 24.6% | A413-2604-B |
| Jun 11 | 700 | 679 | 97.0% | $16.47 | 28.9% | A413-2606-B |
| Aug 5 | 700 | 690 | 98.6% | $16.01 | 30.4% | A413-2608-B |
Rework
319.5 hrs
| Logged | Trigger | Status | What happened | Hrs |
|---|---|---|---|---|
| Aug 7 | Surface | Resolved | Ten parts with die spray streaking on the sealing face. Fix: Spray ratio thinned and nozzle distance fixed at 180mm. Run of Aug 5 | 2.0 |
| Jun 13 | Leak | Resolved | Twenty one parts leaked, same corner, lower rate than the first run. Fix: Vent cleaned between shots. Impregnation on the failures. Run of Jun 11 | 6.5 |
| Apr 17 | Leak | Partial | Thirty nine parts failed the 2.5 bar pressure test at the far corner. Fix: Impregnation sealed twenty two. Seventeen scrapped. Run of Apr 14 | 11.0 |
Porosity observations
3| Logged | Where | Severity | Cause | Fix | Resolved |
|---|---|---|---|---|---|
| Aug 6 | Second channel wall | Minor | Material | Ingot lot quarantined and returned. | Yes |
| Jun 12 | Far corner, at the last point to fill | Minor | Venting | Vent cleaned between shots. | Yes |
| Apr 16 | Third channel junction | Moderate | Venting | Far corner vent opened to 6mm. | Yes |
Post-mortem
completed Aug 14, 2026
- Tooling actual
- $7,188
- Tooling delta
- +$594
- Per piece actual
- $16.72
- Per piece delta
- +$1.47
- Rework cost
- $2,925
- Labour
- 296.5 hrs
What went wrong
The leak rate on the first production run was four times what the trials predicted, because the trials never ran long enough for the vent to load up.
What to do differently
Run a trial batch at production length before quoting a pressure tight part. Short trials hide anything that accumulates.
Notes
Tooling overran by nine percent. Still the largest committed volume on the floor and margin is climbing run over run.
Knowledge from this job
3- Die spray streaking is a nozzle distance problemThinning the ratio to 1:90 and fixing nozzle distance at 180mm. Streaking on the sealing face stopped.Pour
- A vent loads up over a production length runCleaning the far corner vent between shots. Leak rate dropped from six percent to three percent on the next run.Rework
- Impregnation is a decision, not a defaultImpregnating the borderline leakers and scrapping the rest. Twenty two of thirty nine came back and passed.Rework
Job opened Feb 2, 2026 · 3 trials · 3 runs · 1,930 pieces delivered