An aluminum component with intricate passages or pressure-tight requirements leaves little room for process variation. Late-stage issues with geometry, porosity, or consistency put qualification, assembly, and production schedules at risk. The process behind a casting matters as much as the casting itself.

For OEMs and Tier 1 suppliers, that means finding a casting partner with the technical resources, production capabilities, and quality controls to manage demanding requirements from development through production.

Epcor brings these capabilities together, combining in-house simulation and core making with automatic green sand molding, robotic pouring, finishing, and inspection.

THE CAPABILITIES BEHIND CONSISTENT PRODUCTION

• Identify Challenges Before Launch: In-house simulation analyzes metal flow and solidification, giving engineers insight to refine casting designs and production plans before launch.
• Produce Complex Internal Geometries: Shell and cold-box core-making capabilities support intricate passages and highly cored aluminum components, including leak-tight applications.
• Maintain Production Repeatability: Automatic DISA Match and SINTO green sand molding, robotic pouring, and PLC-controlled processes support consistent molding and metal handling.
• Handle Critical Finishing Steps: PLC-controlled core removal, 5-axis CNC sawing, automated trimming, tumble blasting, and machining address requirements beyond the initial casting.
• Verify Quality: ISO 9001:2015 and IATF 16949:2016 quality systems, material analysis, dimensional inspection, traceability, and leak-tight testing support verification against customer requirements.

Put Epcor’s capabilities to work on your next aluminum casting project. Contact our team to discuss your part requirements, production needs, and next steps.