Why swap to a die casting?
Existing fabrications can be redesigned as an aluminium die casting to produce a lighter, serviceable item with good cost savings. Threaded inserts, pins and bushes can be incorporated into the casting design to eliminate machining costs. For example the inclusion of a threaded inserts at the casting stage eliminates the need for drilling and tapping.
The Design process
3D CAD/ CNC files can be created from fabrication samples, sketches, existing castings, drawings or existing data. These files are used to create 3D models so that customers are presented with a visual insight of the design before production. This data can be later used for prototypes and production tooling.
Machining costs on existing designs which are being sand cast can be cut by reducing or eliminating machined faces. Improved accuracy of die castings can reduce machining allowances and in doing so will mean that the final casting weight is lighter – Hence cheaper.
Prototype patterns are machined traditionally from drawings or CAD data. They are produced usually in Ureol, or Resin. They are used to manufacture castings from which the customer can verify the design by fit and function or other testing before laying down production tooling.
Patterns and dies are manufactured on site in our own toolroom. Tooling can be made by traditional methods eg., dies cast to Size in our iron foundry or machined from blanks. Most of the tooling is CNC machined. Dies can be operated mechanically or hydraulically depending upon size, complexity etc.