Build-to-Print Manufacturing: Heat-Resistant Honeycomb Grate For Thermal Storage

We received technical drawings for a sector-shaped honeycomb grate designed for the thermal storage chamber of a hot blast stove. The component is used in a high-temperature, high-load environment, where structural integrity, dimensional precision, and material performance are critical to ensure stable operation.

Requirements

• Material: GH2747 heat-resistant alloy, with composition conforming to national standard GB/T 14992, suitable for high-temperature and high-load applications, ensuring long-term stability under extreme thermal conditions.
• Manufacturing: Castings must be free from cracks, porosity, shrinkage, and other defects. All surfaces require thorough cleaning and finishing. Each piece must meet a controlled weight of 19±0.6 kg to ensure consistency and compatibility during assembly.
• Accuracy: Strict dimensional and geometric control was required, including a casting radius of R ≤ 2 mm, draft angle <1°, maximum warpage ≤ 5 mm, and overall shape deviation within ≤ 0.8 mm. These tolerances are critical to ensure proper installation and system performance.

 

Our Solution

Based on a strict build-to-print approach, we fully manufactured the honeycomb grates according to the customer's technical drawings and specifications. By applying controlled casting processes and rigorous quality inspection at every stage, we ensured high structural integrity, precise dimensional accuracy, and defect-free production. Special attention was given to maintaining dimensional stability during casting and post-processing, as well as ensuring careful handling, packaging, and transportation to prevent any damage during delivery.

Benefits

• All components were delivered intact and fully compliant with the customer's strict technical and quality requirements, ensuring smooth installation and system integration.
• The precision and consistency of the castings met the demands of high-temperature operation, supporting stable performance of the thermal storage system.
• The customer expressed high satisfaction with both product quality and execution capability, strengthening confidence in our manufacturing reliability.

This project demonstrates our capability to deliver complex, high-precision build-to-print cast components for demanding industrial applications. By strictly adhering to technical drawings and quality standards, we ensured reliable performance, dimensional accuracy, and consistent quality, while establishing a solid foundation for future cooperation.