In Detail
Find out more details about our possibilities to make parts from scrap to fully machined.
WE DESIGN
We can either help you to design your part from scratch or redesign your part into a casted part. Your design is sent to us using a solid works file .sldprt, .iges or .step file. We import it into our system and redesign it into a casted part.
If no drawing is available but an old part has to be used, then we start by measuring the part and describing it completely. A 3D drawing of the part is then built and the necessary drawings for making the casted part are made.
Once we have all drawings available it is sent to our pattern making shop to make the patterns and core boxes. If no pattern has to be made then we directly produce the mold from the available drawings.
We also use 3D printing in ABS to make patterns and coreboxes or to produce prototypes or unique ABS parts.
Design
- 3D measuring arm
- CNC measuring machine
- 3D scanning
- Conventional measuring tools
- Solid Works (most recent version)
- 3D printing (ABS)
WE CAST
The decision to build a casting pattern is taken depending on the uniqueness of the part, on the quantity to be casted and on the complexity of the part. Mostly a casting pattern is required as soon as the quantity reaches 25 pieces and is regularly returning. We create a casting pattern either based on our own design files or based on your files. Casting patterns and core boxes are build in wood, plastics or alumnium. This is done in our own workshop. Parts which are casted without casting pattern can be made with an existing part or can be milled. A combination of different techniques for making molds and core is often made. Building molds and cores by milling can be done in different layers or parts, so dimensions are theoretically unlimited.
Once the mold and the cores have been made they are assembled and the part is casted.
After cooling down in the mold the part is removed from the mold and the sand is cleaned off by sandblasting. The part is grinded and painted if necessary.
It is then ready for machining.
We mainly cast :
Ferro alloys :
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Grey cast iron grades
DIN1691 / EN1561:1997
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Ductile cast iron grades
DIN1693 / EN 1563:2011
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Other grades are possible - We do NOT cast steel grades.
Non-Ferro alloys : Aluminium, Bronz, Copper, etc...
Casting
- Ferro & non ferro alloys
- Molds up to 1800 x 1800 mm
- Max. weight 1200 kg
- Hand made molds & cores
- CAM used for making molds
- CAM used for making cores
- Chemically bonded sand
- Electric melting furnaces
WE MACHINE
Once a part has been casted we can fully machine it. We have all necessary machines to deliver your parts within the requested tolerances. (see table on the right).
We regularly machine all kinds of parts amongst which :
- Machine bases
- Pulleys (rope and cable)
- V-Belt pulleys
- V-Belt pulleys for bushes
- Wheels of any kind
- Cylinders
- Welded parts
- Aluminium parts
- and more...
If you prefer we can also deliver fully assembled parts which can include e.i. bearings, bolts, shafts, grease etc...
We are convinced we can find a solution for delivering your completely finished part.
Machining
- Conventional turning Ø1250 mm x 3500 mm
- Horizontal turning Ø1250 mm x 800 mm
- CNC horizontal turning Ø1250 mm x 800 mm
- Conventional tunring Ø800mm x 1500 mm
- CNC turning Ø450 x 800 mm
- CNC Milling X1800 | Y800 | Z800
- CNC Milling X800 | Y600 | Z600
- Drilling
- Keyway cutting
- Static balancing of pulleys/wheels
- Dynamic balancing of pulleys/wheels
- and more...
Quality control
We maintain a strict quality control throughout our production process.
In casting cast iron each batch is checked using the CE-equivalent method. Together with respecting 'the recipe' of the load which is put in the furnace we know the material is according to the requested standard. Afterwards a hardness measuring can be performed to confirm.
During machining all critical dimensions are checked for each part. Since we usually produce small quantities we do not rely on theoretical ideas which would reduce the measured quantity.
Once a part is finished it is again checked using a 3D measuring system.
Quality control
- 3D measuring arm
- CNC measuring 1200x800x800
- Roughness measuring
- Hardness measuring Brinell
- Hardness measuring Rockwell
- Ultrasonic thickness measuring
- Microscopic material structure control
- Conventional measuring tools
- CE control equipment
