Our process of manufacturing aluminum castings is the process of choice for many companies for a variety of applications. For financial, logistical, and technical reasons, our process enables you to Gain The Advantage.
Another way Gupta Permold can meet your most demanding requirements is with flexible production quantities. The activity of some of the castings pictured above range from 250 pcs/yr to upwards of 100,000 pcs/yr. Both are possible due to our innovative mold designs which skillfully balance tooling costs and unit costs.
In our Permanent Mold Process, molten aluminum is poured into a metal mold that rapidly chills the aluminum. This causes the metal to solidify into a very fine-grain texture free of porosity and trapped gas. In turn, this gives our castings superior metallurgical properties, a high degree of pressure tightness, and a strength advantage greater than 15% over sand castings, alloy to alloy.
Machining is a costly operation. Our goal as manufacturing engineers is to minimize secondary machining and its costs by providing close dimensional control, a smooth finish, and total repeatability. Surfaces can be cast truly flat, sometimes even free from any draft or taper by suitable mold design. Time after time, switching from other processes to Permanent Mold has cut our customers' machining costs dramatically.
Perhaps the greatest advantage of our castings is our competitiveness. Reducing machining gives our customers a low unit cost while tooling investments are minimized by our skilled engineering and mold shops. They use their years of experience and extensive knowledge to produce innovative mold designs that result in tooling costs often comparable to sand casting.
One of the most unique advantages of our Permanent Mold Process is the ability to cast molded inserts. As you can see, the casting above is cast with a stainless steel insert to provide an extra-hard, wear-resistant surface while keeping the rest of the part in lightweight aluminum. The casting with 4 brass threaded-hole inserts is designed to provide durable, wear-resistant threads. In high-volume situations, cast-in threaded inserts are sometimes even less expensive than CNC drilling or tapping. Either way, molded inserts are a very potent cost-saving technique available only through Gupta Permold.
Gupta Permold castings have a finish that is fine and smooth enough for O-ring seals and gaskets in many applications. They are also smooth enough to be put against metallic surfaces in mating situations. In addition, our castings always have a clean, silvery appearance that minimizes the need for costly operations like polishing and mass finishing. Moreover, if need be, our castings also can be easily tumbled, painted, plated, anodized, e-coated, polished, and cast with crystal clear letters or logos. Try our Metal Finishing Center if the raw cast finish won't sell your product.
Our castings are made in metal molds so dimensional variation from piece to piece is negligible and close tolerance is consistently held. Our ability to achieve the highest accuracy and precision has allowed us to successfully cast many parts that have been used without machining, resulting in remarkable savings for our customers.
Process control and upfront engineering are the keys to guaranteeing high-quality castings. This is probably why Gupta Permold exceeds the industry standards for internal scrap and failure rates. In summary, Gupta Permold strives for Zero-Defects by continuously monitoring all processing and investing painstaking effort into tooling development and designs.
Our molds are machined out of blocks of high-grade steel. As evidenced by the casting above, complex shapes with thin walls can be cast using ingenious coring techniques so no machining is needed. Undercuts are routinely cast with the use of sand cores, and sometimes, even without. Fully machined cavities, intricate coring techniques, and state-of-the-art molding make complex aluminum parts a routine task for Gupta Permold.