Die Casting

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.

Materials

  • Aluminum
  • Magnesium
  • Zinc
  • Brass
  • Copper

Advantages of Aluminum Die Casting

  • Economical process offering a wide range of sizes and shapes
  • Can provide integral fastening elements as part of the design
  • CNC Machining can be used to further refine the design, if needed
  • Aluminum Die Cast parts are strong and have a long life span
  • Complex shapes with high dimensional accuracy and stability than other mass production processes
  • Aluminum Die Cast parts can be manufactured with smooth or textured surfaces
  • Aluminum Die Cast parts can be easily anodized, painted or powder coated with minimal surface preparation

Our Aluminum Die Casting Capabilities Include:

  • Aluminum Die Casting
  • Aluminum Alloy Die Casting
  • Hot Chamber Die Casting
  • Cold Chamber Die Casting
  • ISO:9001 Certified
  • Engineering Assistance
  • Quality Audits
  • Import / Export Services
  • Global Logistics Management
  • JIT & KANBAN
  • Assembly, Painting & Anodizing
  • Warehousing & Inventory Management

Green Sand Moulding

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.

Materials

  • Aluminum
  • Ductile Iron
  • Grey Iron
  • Stainless Steel
  • Brass
  • Copper

Advantages of Brass Die Casting

  • Economical process offering a wide range of sizes and shapes
  • Can provide integral fastening elements as part of the design
  • CNC Machining can be used to further refine the design, if needed
  • Brass Die Cast parts are strong and have a long life span
  • Complex shapes with high dimensional accuracy and stability than other mass production processes
  • Aluminum Die Cast parts can be manufactured with smooth or textured surfaces
  • Aluminum Die Cast parts can be easily anodized, painted or powder coated with minimal surface preparation

Our Aluminum Die Casting Capabilities Include:

  • Brass Die Casting
  • Brass Alloy Die Casting/li>
  • Hot Chamber Die Casting
  • Cold Chamber Die Casting
  • ISO:9001 Certified
  • Engineering Assistance
  • Quality Audits
  • Import / Export Services
  • Global Logistics Management
  • JIT & KANBAN
  • Assembly, Painting & Anodizing
  • Warehousing & Inventory Management

Investment Casting

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.

Materials

  • Carbon Steel
  • Ductile Iron

Investment Casting Reduces Costs

  • Investment Casting has lower equipment costs
  • Lower cost than machining out of bar stock
  • Investment Castng can produce complicated shapes with close tolerances & fine details
  • Improved surface finishes, saving time and money on final finishing processes
  • Investment casting is material efficient, generating far less waste than wrought processes
  • Saves money when using costly alloys
  • Investment casting can be used to combine multiple parts into a single unit
  • Can produce savings in the number of manufacturing steps

Our Investment Die Casting Capabilities Include:

  • Aluminum
  • Bronze
  • Steel/Stainless Steel
  • Titanium
  • Copper Alloys
  • Nickel Alloys
  • ISO:9001 Certified
  • Engineering Assistance
  • Quality Audits
  • Import / Export Services
  • Global Logistics Management
  • JIT & KANBAN
  • Assembly, Painting & Anodizing
  • Warehousing

Gravity Casting ( Permanent Mold 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.

Materials

  • Aluminum

Advantages of Iron Die Casting

  • Economical process offering a wide range of sizes and shapes
  • Vibration damping
  • Wear Resistance
  • Excellent Machinability
  • High Density
  • High Stability | Minimal Shrinkage
  • Excellent Heat Conduction
  • Corrosion Resistant

Our Iron Die Casting Capabilities Include:

  • Iron Die Casting
  • Ductile Iron Die Casting
  • White Iron Die Casting
  • Gray Iron Die Casting
  • ISO:9001 Certified
  • Engineering Assistance
  • Quality Audits
  • Import / Export Services
  • Global Logistics Management
  • JIT & KANBAN
  • Assembly, Painting & Anodizing
  • Warehousing & Inventory Management

Extrusion

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.

Materials

  • Aluminum
  • Rubber
  • Plastic

Advantages of Zinc Die Casting

  • Low Cost Raw Material
  • Casting Process Flexibility
  • Long Tool Life
  • Fully Recyclable
  • High Precision | Close tolerances
  • Excellent thin wall Capability
  • High Dimensional Accuracy & Stability
  • Superior Strength | Impact Resistant
  • Excellent Corrosion Resistant
  • Thermal & Electrical Conductivity
  • High Quality Finish
  • Easily to Anodize, Paint, or Plate
  • Moderate casting temperatures provide significant energy & processing savings

Our Zinc Die Casting Capabilities Include:

  • Zinc Die Casting
  • Zinc Alloy Die Casting
  • Hot Chamber Die Casting
  • Cold Chamber Die Casting
  • ISO:9001 Certified
  • Engineering Assistance
  • Quality Audits
  • Import / Export Services
  • Global Logistics Management
  • JIT & KANBAN
  • Assembly, Painting & Anodizing
  • Warehousing & Inventory Management

Forging

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.

Materials

  • Stainless Steel
  • Copper
  • Brass
  • Carbon Steel

Advantages of Forging

  • Improved directional, structural & impact strength
  • Pre-working refines defects
  • Reliablity leads to lower costs over component life
  • Better response to heat treatment
  • Production Efficiency
  • Improved Strength
  • Reduced Need for Expensive Alloys
  • Greater Wear Resistance

Our Forging Capabilities Include:

  • Aluminum Forging
  • Steel Forging
  • Stainless Steel Forging
  • Copper Forging
  • ISO:9001 Certified
  • Engineering Assistance
  • Quality Audits
  • Import / Export Services
  • Global Logistics Management
  • JIT & KANBAN
  • Assembly, Painting & Anodizing
  • Warehousing & Inventory Management

Stamping

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.

Materials

  • Stainless Steel
  • Carbon Steel

Advantages of Stamping

  • Cost Efficiency
  • Consistent Quality
  • Fast Setup
  • High Speed, Low Cycle Times
  • Longer Runs
  • Less Material Waste
  • Lower Cost Per Part

Our Stamping Capabilities Include:

  • Brackets/Supports
  • Frames/Braces
  • Electrical/Lighting Components
  • Heat Shields
  • ISO:9001 Certified
  • Engineering Assistance
  • Quality Audits
  • Import / Export Services
  • Global Logistics Management
  • JIT & KANBAN
  • Assembly, Painting & Anodizing
  • Warehousing & Inventory Management

Shell Moulding

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.

Materials

  • Rubber
  • Plastic
  • Polyurethane Foam

Molded Parts:

  • Rubber Gaskets
  • Rubber Door & Window Seals
  • Rubber Grommets
  • Rubber Bellows / Dust Covers
  • Vibration Dampening
  • Bump Stops / Screw Mounts

Materials:

  • Neoprene (CR)
  • Ethylene-Propylene (EPDM)
  • Nitrile (NBR)
  • Silicone (SI)
  • Styrene-Butadiene (SBR)
  • Natural Rubber (NR)

Our Rubber & Plastic Molding Capabilities Include:

  • Large Volume Production
  • Custom Compound Formulating
  • Injection, Transfer & Compression Molding
  • Rubber-to-Metal & Plastic Bonding
  • ISO:9001 Certified
  • Engineering Assistance
  • Quality Audits
  • Import / Export Services
  • Global Logistics Management
  • JIT & KANBAN
  • Die Cutting & Assembly
  • Warehousing & Inventory Management

Precision CNC Machining

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.

Materials

  • Aluminum
  • Copper
  • Carbon Steel
  • Stainless Steel
  • Plastic
  • Brass

Materials for CNC Machining:

  • Steel / Stainless Steel / Steel Alloys
  • Aluminum / Aluminum Alloys
  • Brass
  • Bronze
  • Copper
  • Titanium
  • Die Castings
  • Plastics

Advantages of CNC Machining:

  • Lower Costs on Labor & Materials
  • Speed of Production
  • Complex Shapes Easily Achieved
  • Increased Accuracy
  • Part Consistency
  • Tight Tolerances: +/- .0001″
  • Rapid Protyping

Our Aluminum Die Casting Capabilities Include:

  • Micro-Machining
  • Prototype Machining
  • 3, 4, and 5-axis Machining
  • Tolerances: +/- .0001″
  • ISO:9001 Certified
  • Engineering Assistance
  • Quality Audits
  • Import / Export Services
  • Global Logistics Management
  • JIT & KANBAN
  • Assembly, Painting & Anodizing
  • Warehousing & Inventory Management

Manufacturing Assemblies

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.

Materials

  • Aluminum
  • Brass
  • Copper
  • Magnesium
  • Zinc
  • Carbon Steel
  • Ductile Iron
  • Stainless Steel
  • Grey Iron
  • Powered Metal
  • Plastic
  • Polyurethane Foam
  • Rubber

Advantages of Manufacturing Assemblies

  • Your parts are delivered ready to use
  • Increased manufacturing efficiency
  • Lower lead times
  • Time and money savings
  • Simple or complex assemblies

Our Assembly Capabilities Includem:

  • LED Components
  • Electronic Components
  • Housings
  • Lighting Assemblies
  • ISO:9001 Certified
  • Engineering Assistance
  • Quality Audits
  • Import / Export Services
  • Global Logistics Management
  • JIT & KANBAN
  • Assembly, Painting & Anodizing
  • Warehousing & Inventory Management

Engineering Supply Chain

Request a quote online or call 740-201-8112 today!