Ski-Doo, manufacturer of snowmobile equipment and accessories, wanted to provide its customers with an enhanced front bumper upgrade to the welded tubing bumper that comes standard. A cast version would add a premium look to Ski-Doo snowmobiles, but the conversion had to maintain the safety standards of the welded part. Ski-Doo (a company of AFS Corporate Member BRP) worked with casting supplier Powercast Manufacturing Inc. (St-Eustache, Quebec, Canada), also an AFS Corporate Member. The challenges to creating the cast design included building a foundry tool for the awkwardly-shaped part that ejected the bumper without warping it. With smart casting engineering, the final design met the OEM’s goal.

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