Foundries
The foundry industry produces cast metal components by melting down materials into liquid form, pouring them into molds, and removing the molds once the metal has cooled and solidified. LeanWerks is a trusted partner for machining, assembling, and testing cast components for foundries. With an emphasis on datum structure-based fixturing, we improve machining quality, consistency, and turnaround times, so you can trust that our team will provide the quality products and services you deserve.
For more information about partnering with LeanWerks or to receive a quote for machined castings, contact us today.
Precision Machining for Cast Components
Working with castings comes with its own set of challenges. Irregularities in surface finish, gating, and form variations make workholding a huge challenge. This requires a precision machining partner like LeanWerks with extensive experience in machining castings, a deep understanding of datum structures, and proper ordering of machining operations, all of which allow us to excel at the most fundamentally critical element of machining castings – the machining fixture. Simple or complex, the machining fixture sets the stage for success or failure, and with LeanWerks, you’ll be successful every time.
Our casting processes include:
- Sand casting – good for low volume large parts, rough surface finish, simpler geometry
- Investment casting – high precision parts with complex geometry
- Die casting – high volume tight tolerance parts
- Permanent mold – mid volume capabilities with better properties than sand casting
- Centrifugal – good for cylindrical parts
- Continuous casting – good for raw material shapes, not near finished geometries
Wide Range of Materials
We have the capability to work with a wide range of materials, including cast iron, ductile iron, aluminum, steel, stainless steel, Inconel, specialty alloys, and more. Machining iron castings requires additional machine maintenance, coolant filtration, and exhaust air filtration due to the abrasive nature and small size of the chips created during machining. LeanWerks has dedicated machines for iron machining.
Inspection Fixtures and Functional Gages
Because castings, especially Investment castings, have complex geometries, it is often easier and more reliable to inspect the castings with a dedicated inspection fixture. LeanWerks can manage the design, approval, build, and calibration of functional gauges and inspection fixtures often needed to validate machined castings.
Tight-Tolerance Finishing
Our precision machining methods allow us to achieve tight, consistent tolerances across production runs, accurate dimensions, and proper fit and function within assemblies.
Complex Geometry Machining
Our multi-axis machining capabilities are ideal for intricate features, allowing access to difficult-to-reach surfaces on irregular shapes. This reduces the need for multiple setups, saving time and money in the long run.
Secondary and Special Processes
We also work with a number of NADCAP, Prime, and OEM-approved sources to complete all required operations to finish casting-based components or assemblies, including:
- Anodizing
- Chem Film
- Alodine
- Plating
- Painting
- Passivation
- Shot Peening
- Bead Blasting
- Grinding
- Heat Treatment
- Nitrocarburizing
- Cleaning
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Assembly, Testing, and Quality Assurance Services
We can also perform assembly, testing, and quality assurance services, contributing to shorter lead times and a more streamlined process from start to finish.
From integrating machined parts into subassemblies or finished products to installing hardware, we’ll take care of the assembly process, reducing the need for multiple vendors. We verify that parts and assemblies meet exact customer specifications..
Process Efficiency and Lean Manufacturing
At LeanWerks, we understand the importance of integrating lean manufacturing principles into our machining processes. This starts with grouping parts into families with the same engineered process flow, allowing us to streamline production, reduce cycle times, minimize waste, and maximize material utilization. We aim to decrease turnaround times while continually improving the quality and efficiency of our services.
Why Choose LeanWerks for Foundry Industry Manufacturing?
At LeanWerks, we can support both low-volume and high-volume foundry projects. We’re able to adapt to fluctuating demand and production schedules while maintaining consistent quality and precision across all production runs. With our extensive experience working with the foundry industry, you can trust that we have the specialized knowledge and solutions you need.
If you need a precision manufacturing partner, contact LeanWerks today to learn more about our foundry-specific services and receive a quote for your next project.
Frequently Asked Questions
What industries rely on machined castings?
Machined castings are widely used in industries such as aerospace, space, defense, energy, oil and gas, automotive, heavy equipment, agriculture, and industrial manufacturing. These industries depend on the combination of intricate form, strength, and the economies of scale that machined castings provide.
What are the benefits of working with a single machining partner?
Partnering with a single provider for machining, assembly, and testing simplifies logistics, reduces lead times, and improves quality control. It ensures better communication and consistency throughout the entire production process.
What role does machining play in the foundry industry?
Machining is a critical secondary process that brings cast parts to their final dimensions and specifications. While castings are formed near net shape, precision machining ensures tight tolerances, proper surface finishes, and functional features like holes and threads needed for assembly and performance.