Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process.
Most die castings are made from non-ferrous metals, depending on the type of metal being cast, a hot- or cold-chamber machine is used.
Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand as the mold material. Sand castings are produced in specialized factories called foundries.
Sand casting is used to produce a wide variety of metal components with complex geometries. These parts can vary greatly in size and weight, ranging from a couple ounces to several tons. Some smaller sand cast parts include components as gears, pulleys, crankshafts, connecting rods, and propellers. Larger applications include housings for large equipment and heavy machine bases. Sand casting is also common in producing automobile components, such as engine blocks, engine manifolds, cylinder heads, and transmission cases.
Investment Casting, also known as Lost Wax Casting, is a precision casting process that provides design flexibility and significant cost advantages.
The Investment Casting process involves pouring molten metal into a mold that has been created using a wax model. Once the mold is made, the wax model is melted and drained away. Hollow cores can be effected by using a heat-proof core that prevents the molten metal from totally filling the mold.
Investment Casting is generally used for small castings, but can be used to produce much larger components.
Dimensional tolerances of ± 0.003 in./in. are readily achieved. Delicate parts with walls as thin as 0.025 in. can be achieved by investment casting.
Gravity casting is a metal casting process that shares similarities to both sand casting and die casting. Sometimes referred to as Permanent Mould.
Gravity casting is typically used for high-volume production of small, simple metal parts with uniform wall thickness. Non-ferrous metals are typically used in this process, such as aluminum alloys, magnesium alloys, and copper alloys. However, irons and steels can also be cast using graphite molds. Common permanent mold parts include gears and gear housings, pipe fittings, and other automotive and aircraft components such as pistons, impellers, and wheels.
Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed through a die of the desired cross-section.
The process begins by heating the stock material (for hot or warm extrusion). It is then loaded into the container in the press. A dummy block is placed behind it where the ram then presses on the material to push it out of the die. Afterward the extrusion is stretched in order to straighten it. If better properties are required then it may be heat treated or cold worked.
The extrusion ratio is defined as the starting cross-sectional area divided by the cross-sectional area of the final extrusion. One of the main advantages of the extrusion process is that this ratio can be very large while still producing quality parts.
Forging is a manufacturing process involving the shaping of metal using localized compressive forces from a hammer or a die. MES provides hot forging, warm forging and cold forging.
Widely used in mechanisms and machines wherever a component requires high strength, forging can produce a component that is stronger than an equivalent cast or machined part.
Forging offers uniformity of composition and structure. As the metal is shaped during the forging process, its internal grain deforms to follow the general shape of the part. As a result, the grain is continuous throughout the part, giving rise to a piece with improved strength characteristics. This strengthens the resulting steel product particularly in terms of impact and shear strength.
Stamping is the process of placing flat sheet metal in either blank or coil form into a stamping press where a tool and die surface forms the metal into a net shape.
Stamping includes a variety of sheet-metal forming manufacturing processes, such as punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. Stamping is either a single stage operation where every stroke of the press produces the desired form on the sheet metal part, or a multiple stage process.
Stamping can be applied to a variety of materials based on their unique metalworking qualities for a number of applications.
Injection molding is a manufacturing process accomplished by forcing raw, uncured rubber into a heated mold using a reciprocating screw. The material is formed and cured under heat and pressure, then removed to cool as a custom shape.
Compression molding uses a pre-measured amount of raw rubber material that is placed into a heated open lower mold cavity. The top cavity is then forced closed, causing the raw material to flow through the shape of the mold.
In transfer molding, rubber is measured, heated and forced into chamber. A plunger is used to force the material into the mold using a system of runners and channels to thoroughly fill the closed mold. The mold is heated to cure the raw material.
The CNC Machining process is more precise than manual machining, and can be repeated in exactly the same manner over and over again.
Because of the precision possible with CNC Machining, this process can produce complex shapes that would be almost impossible to achieve with manual machining.
CNC Machining is used in the production of many complex three-dimensional shapes.
Because of the accuracy, close tolerances and repeatability, CNC Machining is used in jobs that need a high level of precision or very repetitive tasks.
MES can perform a wide range of assemblies, from simple two component assemblies to complex assemblies. Quality assurance processes are in place to ensure the consistent quality of each assembly.
We provide fabrications and assemblies which meet your specifications and tolerances. We will determine the most efficient manufacturing and assembly process, produce the components, manage your supply chain process, including inventory management, and provide high quality fabrications and assemblies.