Method and system for manufacturing a coupler knuckle

A method for manufacturing a railcar coupler knuckle, comprising:

• providing a cope mold portion and a drag mold portion, the cope and drag mold portions having internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity;
• positioning one internal core within either the cope mold portion or the drag mold portion, the one internal core configured to define a kidney cavity, a finger cavity and a pivot pin cavity within a coupler knuckle;
• closing the cope and drag mold portions with the one internal core therebetween;
• and
• at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle wherein the internal core comprising:
• a kidney portion configured to define the kidney cavity of the coupler knuckle;
• a finger portion configured to define the finger cavity of the coupler knuckle;
• and
• a pivot pin portion configured to define the pivot pin cavity of the coupler knuckle.