With our extensive experience, we at Perla AluCast know exactly what you need during the development and production of aluminium castings. We can assist you at every stage of the aluminium casting process. Compared to other aluminium foundries, we go the extra mile with the help of a comprehensive ten-step plan.
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After you submit your request, we will begin by determining the product requirements that have to be met. The intended function of your aluminium casting is a deciding factor here. For example, it is important to assess the required degree of water resistance (also known as the IP class). We must also determine the product's desired resistance against corrosion and other outside influences. By defining the product requirements at this early stage, you can realise significant cost savings at the end of the casting process. Once all product requirements are clearly defined, we can move on to step two.
Do you already have an initial design for the product you want to cast in aluminium? If so, we can provide input on how to optimise the casting's design for production. This ensures the product can actually be produced and helps us determine what casting method is best suited for your aluminium casting. It also helps to minimise the risks during production and will lead to a better end product.
Once the design has been approved, we will create 3D models of the aluminium casting. These models are fully tailored to the casting process that was chosen. We use the CAD system; a handy tool for creating 3D designs. We also perform various tests, such as a strength analysis with the help of FEM analysis. Once the 3D models are done, we can create a prototype of the casting to check any last imperfections in the design. We will also create 2D drawings and define the desired dimensional tolerances.
During the fourth step of the aluminium casting process, the design of your casting is finalised and - as we call it - frozen. This is done once the design process for the aluminium casting is complete and we are both entirely satisfied with the final design. Once the design has been finalised and frozen, we can officially conclude the design process. Next, we will create a product file and draw up a planning. With this planning in hand, we can begin producing your aluminium casting. It also gives you insight into the timeline of the production process.
We begin the production process by creating the mould based on the design of your casting. With their years of experience, our experts know exactly what potential issues may arise during the production and use of the mould. By devoting special attention to these issues at this stage of production, we can prevent any further issues down the line. Even in this phase, we test the mould's functionality using special software.
Once the mould's design is complete, we can begin its production. This is done at our aluminium foundry. Mould production usually has a lead time of six to eight weeks, depending on the complexity and size of your product. Because we produce the mould ourselves, you can rest assured that your mould will be delivered on time. At this stage, it is essential to make sure the mould meets all requirements.
Once the mould is ready, we can officially begin producing your aluminium casting. We will start by performing a test casting with the mould. This is done to check the flow of material inside the mould. It allows us to check the venting of the mould beforehand and look for the presence of trapped air. We can also carefully determine the position of the venting. If necessary, we will modify the design of the mould accordingly. We will send you the test castings for approval, including the measurement report and - if necessary - a material certificate.
Once you have approved the test castings, the mould will receive its final hardening. If you wish, we can then produce a 0 series of your aluminium casting. You can use these products to perform physical tests and set up your own (assembly) processes. We can use the products from the 0 series to optimise our own finishing moulds and fitting gauges.
Once we have agreed to the terms of the first delivery, we will draw up and share the planning for the production process. Based on this planning, we will begin the first full serial production run in our aluminium foundry. Once production of the first series is complete, we will perform a final inspection with the help of the product file. As a result of our close collaboration during all previous steps and the interim inspections we perform, most first series we produce are free of defects or other issues.
Once the products have passed their final inspection, it is time to ship them back to the Netherlands. We will transport your products from our aluminium foundry to our warehouse in Sliedrecht. If you want your products to be delivered to a different location, in special units or on the same day every week, that is also possible. We can also keep your products in stock at our location in Sliedrecht to ensure they are always delivered just in time.
Would you like to know more about what our aluminium casting process can do for you? Contact us without any further obligation. Call us at +31(0)15 203 3100, send an email to expert@perla-alucast.nl or fill out our contact form. We are happy to help!
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