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Waukesha Foundry |
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Advanced Technologies |
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Extensive Manufacturing |
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Our extensive manufacturing capabilities allow us to produce castings in over 200 different alloys, ranging from one to 6,000 pounds. Waukesha Foundry is a single-source supplier for value-added operations such as polishing, painting and machining, so even challenging orders are delivered on time and on budget. Four Molding Processes Chemically Bonded Sand – Achieves superior mold strength and dimensional stability with excellent surface quality. This process uses a combination of high-grade silica sand and chemical bonding agents in manufacturing molds up to a 102-inch square. With a relatively low start-up cost, it is an excellent choice for low- to medium-volume production. Cores are produced in a variety of processes, including oil sand, no-bake and shell. Patternless – Waukesha Foundry features state-of-the-art robotic cells, which allow us to take customers' CAD data and convert it into machine paths so we can machine customers' geometries directly into sand mold blanks. This new technology eliminates the need for conventional pattern equipment, plus significantly reduces costs and lead times, making it ideal for low-volume production runs where a customer may need to order only one or two parts at a time. Also, efficiently accommodates high-volume production runs. Replicast™ – Allows us to cast thinner sections and internal features while reducing machine stock, resulting in a lighter weight design with near net shape. Replicast's advantages make it an excellent choice for low- to medium-volume production runs as well as rapid prototyping. It is also a good option for high-volume applications, which are not suited to other casting processes. Resin Shell – Applies heat-activated, resin-coated sand to a pre-heated metal pattern. The rigidly bonded sand provides great reproducibility and produces castings nearer to net shape with intricate detail, superior dimensional accuracy and surface quality. The Resin Shell process is an excellent choice for medium- to high-volume production. Investment Casting Resource - Provides supply line and foundry expertise for your investment casting procurement. Solidification and Solid Modeling - need info Melt Capacity - With nine furnaces ranging from 300- to over 4,000-pound capacities, we can adjust by both weight and alloy to pour castings varying from one to over 6,000 pounds in order to accommodate low- to high-volume production runs. P&W Machine, Waukesha Foundry's in-house machine shop, provides casting services, including rough and/or finish machining, Blanchard grinding, polishing, fabrication welding and assembly. |
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