It is becoming increasingly common for a customer to require a fully finished part ready for assembly in their business. Historical issues with multiple sub-contract stages for casting, machining and paint finishing lead to excessive costs from transport and similar inefficiencies. These result in build-ups of lead times and, thusly, a loss of control and communication regarding the whereabouts of the part within the production process. Having all processes on site helps drive down production lead times, as we can start to machine parts even before the whole batch has been completely cast – it is not uncommon to be casting, heat-treating and machining the same parts to deliver an order to a customer as quickly as possible.
A crucial part of our role as a modern non-ferrous (mainly aluminium) foundry is to ensure that our castings can be machined to the highest standard on site, and offer as much of the supply chain to our customer as we can and they require. As such, we have invested considerably in our machine shop, which comprises state of the art CNC milling and CNC lathe turning facilities. Our pallet changing vertical and horizontal CNC production centres offer continuous machining for higher production (increased metal cutting time) – saving the time lost loading – especially with higher volume runs.
Our highly trained staff have experience producing both large batches of metal alloy components and individual bespoke pieces to an equally high standard, and our lathe turning facilities are capable of producing finished aluminium castings (or from solid materials) in a range of sizes – for examples of our capabilities please see our plant list.
Here at Foundry & Fabrication, not only do we machine our own aluminium castings, but we also offer subcontracting out CNC milling and CNC lathe turning capacity to other foundries and machinists. Our experience in machining castings covers a range of different shapes and sizes, and has to take account of possible clamping distortion that is often not experienced when machining from solid bar and billet.
Tool making encompasses both pattern making and the machining of the metal gravity dies. In much the same way as with CNC machined patterns, 3D models are used to create the CNC cutter paths needed to machine the cavities in gravity dies. Generally made from cast iron we are able to adjust existing tools as well as commission new ones.
Wherever possible, we keep the tool and pattern making part of the process in-house, both to help preserve our high standards of production and also to help keep the costs down for our customers. However, we have a variety of suppliers who we have used for many years, who know what is required to provide us and our customers with quality services at a competitive price.
We can help manage your project right from the initial stages of design, through to the final bronze or aluminium casting. In addition to more conventional 2D drawings used to design patterns for sand castings and so on, Foundry & Fabrication can also utilise modern technologies such as CAD / CAM data to help realise your concept as accurately as possible.
The use of computer modelling has revolutionised the design of castings and in more recent years, the manufacturing of the patterns required. Here at Foundry and Fabrication, we are able to take your designs and transform them into the finished article, whether by using your three-dimensional models or – if you have only 2D drawings or concepts – by drawing them up into 3D so you can visualise the finished part before manufacture is commenced. The use of models and CNC machining of the patterns in model boards (hard plastic style materials) enables a more accurate part and better quality finish.
Whilst this is often the preferred way to operate, we are still able to make or refurbish patterns by the traditional hand-skilled patternmakers. The better the pattern, the better the finished part.
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