Type of Castings

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Different Types Of Casting To Suite Your Casting Necessity

There are different processes that can be used in creating complex shapes of metals parts and one procedure is through casting. Casting is a manufacturing method wherein a liquid material is transfer

red into a mold, usually following a hollow cavity of the desired shape, and then allowed to solidify afterwards. It has been used even in the past and one example or type of casting is die-casting.

The die casting method is a process of forcing molten metal under high pressure into mold cavities similar to permanent mold casting. It best suites the purpose of making small to medium sized parts fashioned with good and precise details. By-products of this method are furnished with fine exterior finish and dimensional accurateness. Most materials used in this method are metals such as zinc die casting, copper, and aluminium die casting and magnesium die casting.

Another form of casting which is considered to be the most popular and simplest type is sand casting. It is a technique that has been used for many centuries now. Sand casting is a process of forming a mold out of a sand mixture through pouring a casting liquid into a desired shape. This type of casting allows manufacturers to create large number of products in such a small range of production expenses. Most metals are caste depending in the type of sand used for the molds in this method.

An additional process that can be also used is Plastic molding. It is a manufacturing technique in making parts from both thermoplastic and thermosetting plastic materials for production. It includes plastic injection molding wherein molten plastic is injected at high pressure into a mold, which is the opposite from the product’s actual shape. Example by-products of this method are bottle caps and outdoor furniture.

Moreover, a further technique is cold forming. It is also known as cold forging. Cold forming is a manufacturing procedure in which a metal is shaped at an ambient temperature to produce metal components in a definite shape. The techniques usually involved in this procedure are bending, cold drawing, cold heading, coining extrusion, thread rolling and others.

Some benefits of cold forming are enhancements in the component properties of the product because the grain structure of the material is being elongated during the formation process wherein it is forced to follow the structure and as a result its’ strength is increased. Another benefit of cold forming is that the aesthetic finish of the components gives out a brighter facade and formed with a consistent high tolerance. These somehow reduce the necessity of complex finishing and polishing.

These are only some of the different kinds of casting. Other types of casting aside from die-casting, cold forming and sand casting of metals are plaster casting, shell molding, investment casting, permanent mold casting, centrifugal casting, continuous casting and casting of plaster, concrete, or plastic resin. Each type of technique has specific and unique routine that allows you to produce superior outcome and high-quality by-products to best suite all your casting needs for your manufacturing use.

Plastic Molding Manufacturing

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Plastic Molding Manufacturing & Design

Many projects have come to us without the ability to manufacture the product the way the customer had intended. Largely due to the customers lack of knowledge in the plastic molding manufacturing processes when it come the plastic injection molded. Several projects have been renewed when it was discovered by our engineering department that the mold had been gated wrong and this lead to the part having too much stress molded into the part for the finished product to survive in its intended environment.

We pride ourselves in helping the customer by becoming involved early in the process of product design to help prevent end use product failures. One of our best customers asked us to bid on a project that others had already submitted their bids and the customer was complaining about not understanding what made the project so costly. We decided that before we would submit a bid that we would have to sit with the engineer at our customers facility and find out what the expectations were and see if we could find a way to help reduce the cost. As it turned out all that was needed was our engineers to sit with their engineers and we discover that one wall sections in the very complicated part, needed to be moved slightly so that the part did not have an undercut section requiring a side-core in the mold. The customers’ engineer had no problem with the slight modification which as it turned out was all it took to make the part cost justifiable. We got the order.

As we followed up on the sales engineering visit that produced this order we asked why such an obvious change had not been seen before we showed up in their engineering department. The answer was, “because you were the only people that bothered to show up and ask the questions and sit with our engineers.”

We like early involvement. We know how to make a product more manufacturability.

Advanced Quality Planning (AQP)

The ultimate objective of the Advanced Quality Planning system is to launch new plastic mold and plastic products with designs and mold and molding manufacturing processes that insure all cost, quality and delivery expectations of our customers are met. Cross functional teams who use checklists, question/action plans and team inputs to develop Process Flow, FMEA, Process & Inspection sheets, and tools and gauge plans accomplish this. The cross-functional teams consist of representatives from all of our internal departments and the customer. They make use of the best practice manuals, quality history and error proofing to identify the design and process that will provide zero defects at competitive prices.

Sample Submission/Dimensional Layouts

This discipline is responsible for PPAP scheduling, Project Management and complete PPAP certifications of all new and changed plastic parts per the AIAG PPAP requirements Dimensional layout of all plastic mold and plastic molding products is accomplished using traditional equipment as well as state-of-the-art measuring equipment, such as CMM analysis.