Rack Mount Ear
CompleteA380SimpleHealthyrack-mount-ear
Where this job stands
The easy one. Eight up in the cavity, first trial graduated, no rework across the whole run.
Commercial
- Tooling cost
- $6,538
- Committed volume
- 4,000 pcs
- Quote
- Q-2602-HALC-02Manual
- Quoted per piece
- $4.65
- Break-even against CNC
- 527 pcs
- Rework buffer
- Not included
Geometry
- Solid volume
- 21,800 mm3
- Intersection volume
- 24,400 mm3
- Bounding box
- 96 x 44 x 12 mm
- Casting weight
- 0.067 kg
- Parts per mold
- 120recomputed 120
- STEP file
- uploads/halcyon/rack-ear-r1.step
Casting trials
1| Trial | Date | Outcome | Goal | Pour | Mold |
|---|---|---|---|---|---|
| T1grad | Feb 24 | Success | Confirm eight up in the cavity fills evenly. | 680C | 190C |
Production runs
299.5% yield
| Date | Ordered | Delivered | Yield | $/pc | Margin | Batch |
|---|---|---|---|---|---|---|
| Mar 10 | 2,000 | 1,986 | 99.3% | $4.88 | 41.3% | A380-2603-A |
| May 21 | 2,000 | 1,994 | 99.7% | $4.74 | 42.7% | A380-2605-A |
Rework
12.0 hrs
| Logged | Trigger | Status | What happened | Hrs |
|---|---|---|---|---|
| Mar 12 | Dimensional | Resolved | Fourteen parts short on the slot depth at the end of the run. Fix: Scrapped. Tool wear on the slot core, replaced. Run of Mar 10 | 2.0 |
Porosity observations
1| Logged | Where | Severity | Cause | Fix | Resolved |
|---|---|---|---|---|---|
| May 22 | Slot root | Minor | Material | Degassing added to the melt cycle. | Yes |
Post-mortem
completed Jun 4, 2026
- Tooling actual
- $6,179
- Tooling delta
- -$360
- Per piece actual
- $4.81
- Per piece delta
- +$0.16
- Rework cost
- $300
- Labour
- 83.0 hrs
What went wrong
Tool wear on the slot core showed up late in the first run and cost fourteen parts before anyone caught it.
What to do differently
Put a slot depth check on the run sheet every two hundred parts, not just at the start and end.
Notes
The reference job. One trial, graduated straight to production, margin above forty percent on both runs.
Knowledge from this job
0Nothing captured against this job yet.
Job opened Feb 6, 2026 · 1 trials · 2 runs · 3,980 pieces delivered