aluminum sand castings, finishing & prototyping for many industries

NEWS

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Elevate Your Expectations with Epcor Foundry

Discover superiority in every aspect of your journey with us. From seamless delivery to uncompromising quality unparalleled customer support, Epcor Foundry sets the standard for innovation and reliability. Our commitment to timely delivery ensures your projects stay on track, while our unwavering focus on quality guarentees exceptional results every time. With dedicated customer support at your fingertips, you can trust Epcor Foundry to be your partner in success.

Experience the Difference,
Choose EPCOR Foundry for a journey defined by excellence.

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Welcome to Epcor Foundry

Ready for a reliable partner from launch to production on new and transfer projects?
Questions about retooling or resourcing current aluminum casting programs?

NEW PROGRAM LAUNCH RISK ANALYSIS

Does your program meet these standards?

  • IATF Certified for quality and consistency
  • Domestic Supplier
  • Financial Stability
  • Open Capacity
  • World Class PPM
  • Fastest Lead Time for Program Launch
  • Safe Shipping Routes

Contact us for solutions on retooling or launching your next project. Our Epcor Foundry team is ready to ensure unparalleled service to turn your concepts into reality.

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We Wish You a Wonderful Holiday Season!

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Tradition.
Passion.
Commitment.

Where others struggle, Epcor brings solutions!

No other aluminum sand foundry understands complex aluminum castings like Epcor Foundry. We tackle the projects that others shy away from.

Epcor Foundry Brings:

  • A passion for integrating concepts into production solutions
  • In-house tooling design and manufacturing
  • Simulation software to optimize the process parameters
  • The lowest cost U.S. sourced castings

We know how to keep your production up and running reliably every day.

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What Are Your Aluminum Casting Challenges?

We understand the unique challenges our customers face, particularly with higher levels of design complexity.

Epcor Foundry has the necessary engineering, quality, and customer service expertise to support your needs.

  • Epcor is IATF 16949:2016 certified
  • Our in-house foundry tooling division allows complete control and flexibility when speed-to-market is so critical.
  • Epcor's history in aluminum sand casting involves advanced engineering with the most complex casting designs in the industry.
  • ur teams are dedicated to satisfying customer needs from the point of RFQ through the life of the program.

Let's talk about your challenges: Contact Us

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Epcor Simulation Analysis
Essential for Perfecting Your Casting

Staying ahead of the curve is not just an advantage—it's a necessity. Epcor utilizes industry leading simulation software on each program launch.

Problem Solving at The Start
By visualizing the metal flow, cooling, and solidifying processes, we can anticipate and address potential challenges before they arise.

Cost and Risk Mitigation
By simulating parts upfront, we drastically reduce the risk and total costs across your program’s life.

Rapid Production Readiness
This analysis ensures quick turnarounds without sacrificing quality, helping you stay ahead.

Contact Us

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Flexible Production & Fast Response

We understand the importance of adaptability and quick response times in today's competitive market. Our state-of-the-art facility enables us to offer flexible production solutions. This allows us to cater to diverse volume scenarios, from low to high volume production requirements. With advanced technology and capabilities, we can handle customized and standard casting needs with the utmost quality and consistency.

Connect with us to discuss how Epcor Foundry can contribute to the success of your projects

Contact Us

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Complex High-Performing Aluminum Castings to Meet Your Production Needs

At Epcor Foundry, we understand the unique challenges our customers face, particularly when it comes to higher levels of design complexity.

Whether you require pressure-tight applications, thinner-walled sections, or highly complex coring, our experienced team is ready to tackle these challenges.

We would be delighted to discuss how Epcor Foundry can contribute to the success of your projects.

Contact Us

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Advanced Technology & Processes to Deliver Highest Quality Castings

Epcor is committed to continued capital investment in automation technology, process improvement, and lean manufacturing. This enables us to provide you with the highest-quality aluminum castings at competitive prices.

Our Program Management Includes

  • Advanced Product Quality Planning
  • World Class Tooling And Casting Simulation
  • Engineering Design
  • IATF 16949:2016AND IS0:9001:2015 Certified

EQUIPMENT
Our DISA Match and SINTO molding machines are the most precise and technologically advanced, optimizing mold quality and uptime to provide you with an uninterrupted supply of castings to keep your production lines running. Our shorter lead times put castings in your hands sooner.

We have the resources to solve your casting challenge.

Contact Us

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Where Innovation Meets Efficiency
Providing Comprehensive Solutions for All Your Manufacturing Needs

Our Key Perspectives

Quality:
IATF 16949:2016:2016 and ISO:9001:2015 certified, the automotive industry's most widelty used international standard for quality management.

Support:
Customer support and program management - We take pride in satisfying our customers' needs from the point of purchase order, project launch, and mass production.

Manufacturing:
Manufacturing of complex aluminum casting for various industries - highly-cored/pressure-tight applications.

Expertise:
Engineering support and expertise - in-house simulation and pattern division allows complete control and flexibility. This is important for our customers especially when timing and speed to market are critical factors.

Contact Us

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Epcor Foundry Wishes You A Happy St. Patrick’s Day

YOUR TRUSTED SOURCE FOR QUALITY

At Epcor Foundry, our success comes from our high quality controls, an engineering team that is second to none, and our passion to make better parts at a lower price. Let us show you what manufacturing ingenuity is all about...come visit us in Ohio!

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TRADITION + LEADERSHIP + GROWTH + TEAMWORK = SUCCESS!

We Focus On Solving Your Manufacturing Needs With Highly Specialized, Application-based Solutions.

Part 1 – COMPANY BACKGROUND

  • As a leader in the aluminum casting industry slnce 1946, Epcor Foundry offers complex aluminum sand castings with in-house simulation, engineering, and tooling manufacturing.
  • Leverage four generations of expertise with Epcor – where a passion for manufacturing innovation is our tradition.
  • At Epcor, we emphasize the importance of teamwork and the interdependence of its departments and teams.
  • Our culture is one of pride of ownership, demonstrated by company leaders and instilled in all levels as we grow as an organization.

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We Wish You A Wonderful Holiday Season!

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Need an expert to solve your toughest aluminum casting challenges?

The benefits of working with Epcor Foundry and our in-house tooling division are substantial and critical to partners across many different markets.

  • Flexibility – Ability to make timely decisions in-house and offer the solutions needed whether you require new tooling builds or are resourcing tooling.

  • Single-Point Communication – The ability to communicate with the same people in charge at every phase of your project.

  • Technical Resources – Our simulation experts solve problems on the front end of the casting launch to assure success throughout the life of the program.

  • Speed – Agility to accommodate your needs, especially when time constraints are at hand.

How can we help you with your project?

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What is your aluminum casting challenge?

We have the solutions!

In the casting world today, we hear about many problems such as supply chain risks, lead times, and line down threats. Companies are on the move in search of a viable solution, but what steps need to be taken in order to make the best foundry decision for your company?

Part 2 - Does your foundry possess the automated processes and controls needed in today’s stringent manufacturing requirements

Epcor has solutions such as:

  1. Best practices in automatio

  2. PLC based monitoring and control of all internal processe

  3. Continuous screening of sand systems, a critical part of achieving the highest quality casting

  4. Automated 5-axis CNC saw and trim cells for precision cutting and finishin

Thank you for trusting Epcor Foundry. Let's talk about your challenges!

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What are your aluminum casting challenges?

We have the solutions!

In the casting world today, we hear a lot of keywords such as supply chain risks, time constraints, and line down threats. Companies are on the move in search of a viable solution, but what steps need to be taken in order to make the best foundry decision for your company?

Does your foundry have the necessary engineering, quality, and customer service expertise to support your needs?

  1. Epcor is IATF 16949:2016 certified.

  2. Our in-house foundry tooling division allows complete control and flexibility when speed-to-market is so critical.

  3. Epcor's history in aluminum sand casting involves high-level engineering with the most complex casting designs in the industry.

  4. Our teams are dedicated to satisfying customer needs from the point of purchase order, project launch, through mass production.

Thank you for trusting Epcor Foundry. Let's talk about your challenges!

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WHAT DO GREAT ALUMINUM FOUNDRIES DO?

Part Four - Holistic Approach to Supplier Selection

What are key factors you consider when selecting an aluminum foundry as a partner? How do these factors mitigate risk and maximize a successful mutual relationship?

  • Diversification – A foundry that diversifies customers and markets reduces the likelihood of its collapse during a downturn. Because of diversification, the company is prepared to effectively pivot and adjust to changing conditions, while remaining profitable and continuing to deliver to customers.

  • Vision – Improves the company's trajectory and provides a blueprint for future change and expansion based on a wide array of market requirements.

  • Investment - Continuing to invest in processes, operations, quality, and capital equipment provides the foundry with the potential to remain ahead of the competition and increase the likelihood that they can meet your needs as a casting supplier.

Contact Epcor and Let’s Win Together

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WHAT DO GREAT ALUMINUM FOUNDRIES DO?

Part Three – Why is Customer Service More Important Now Than Ever Before

Good foundry owners and leaders always demonstrate integrity with the decisions they make. Customers desire the opportunity to trust and succeed with companies they count on.

  1. Partnership versus Supplier/Customer – Enables a collective team approach with focus on mutual success through all aspects of the relationship. This partnership makes even the most difficult decisions easier to make.

  2. Transparency in everyday operation – The sharing of information and timeliness is critical for companies to succeed together. Processes designed to make production run smoothly, while helping spot potential issues, prevents bottlenecks and delays - before they turn into bigger issues

  3. Trusted Advisor - Foundry leaders and key players involved take on the role of a trusted advisor and subject matter expert to utilize experience and skills to help the customer succeed. Leveraging expertise from both sides makes everyone more successfu

Contact Epcor and Let’s Win Together

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WHAT DO GREAT ALUMINUM FOUNDRIES DO?

Part Two – Leadership and Placement of Value on Human Resources

  1. Holistic Approach to Operations – Good foundry leaders and owners emphasize the importance of the whole organization and the interdependence of departments and teams

  2. Employee Engagement Internally and Externally – Enables foundry employees to be "envoys" of the company name.

  3. True Ownership at All Levels of the Foundry - Pride of ownership demonstrated by company leaders carries through to all levels of the organization.

  4. A Passion for Growth – Spread positivity and encourage innovation throughout the organization!

Contact Epcor and Let’s Win Together

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WHAT DO GREAT ALUMINUM FOUNDRIES DO?

Part One – Staying Ahead of Competition and Leading in Industry

  1. QUALITY - Epcor is IATF 16949:2016 certified, the automotive industry's most widely used international standard for quality managemen

  2. ENGINEERING - support and expertise includes in-house simulation and transparency of knowledge to collectively make the best decisions based on the customers needs.

  3. SPEED-TO-MARKET - pattern division under ownership allows complete control and flexibility to maximize the benefit of time for the customer

  4. CAPITAL INVESTMENT - in automation technology and process improvement is recognized as a continuous commitment to excellence

Contact Epcor and Let’s Win Together

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Your Lowest Total Cost U.S. Production Source Wishes You A Happy St. Patrick's Day!

Your Trusted Source For Quality

Epcor Foundry is your low cost U.S. source.

At Epcor Foundry, our success comes from our high quality controls, an engineering team that is second to none, and our passion to make better parts at a lower price. Let us show you what manufacturing ingenuity is all about...come visit us in Ohio!

LET'S CONNECT

LEARN MORE

IATF 16949:2016 CERTIFIED

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A World Class Foundry such as EPCOR Can Help You Stay Ahead of Competition and Win Business

  • Quality – Epcor is IATF 16949:2016 certified, the automotive industry's most widely used international standard for quality management.
  • Engineering support and expertise includes in-house simulation and pattern division allowing complete control and flexibility, critical where timing and speed-to-market are of the essence.
  • Complex aluminum castings for various industries - highly-cored / pressure tight applications are where we excel.
  • Committed to continued capital investment in automation technology, process improvement and lean manufacturing.

Let's Win Your Next Project – Together!

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Turn Your Challenges Into Opportunities

Three Generations of Aluminum Sand Casting Knowledge and Expertise Make Epcor Your Trusted Partner

What is the Epcor Advantage?

  • Our pattern division supports the shortest production readiness lead-times to help you win business and provide uninterrupted casting supply on current production transfer projects
  • By virtue of automation and process development, we can support your requirements given any volume scenario
  • Simulating your parts up-front provides you with less risk and total cost for the life of your program
  • Develop and manage the right supply chain to fulfill your requirements and assure performance

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HAPPY NEW YEAR!
Now is a great time to look at bringing your castings back to the U.S.!

Have questions about reshoring aluminum sand casting work?

Is the timing right for a solid US-based alternative solution?

Epcor Foundry has the resources you need to make a successful transition, especially those challenging complex applications that aren’t for everyone. Whatever your industry, let us help you!

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We Wish You a Wonderful Holiday Season

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Navigating the Road of Casting Manufacturing Doesn't Have to be Difficult

Epcor provides you with the best technical and human resources to accomplish your manufacturing goals

  • Three generations of casting manufacturing innovation and integrity
  • Engineering led/people-oriented
  • Process improvement through automation and team training/education
  • In-house simulation, tooling design and manufacturing

Contact Us

IATF 16949:2016 Certified

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When others struggle...WE BRING SOLUTIONS!

Tradition. Passion. Commitment.
No other US based aluminum sand foundry understands complex aluminum castings for the Pump & Valve, Filtration, Fuel Transfer and Heat Exchanger industries like Epcor Foundry. We tackle the projects that others shy away from.

  • A passion for integrating performance concepts into production solutions
  • In-house tooling design and manufacturing
  • Simulation software to optimize the process parameters
  • Providing the lowest cost U.S. sourced castings

We know how to keep your production up-and-running reliably every day.
Protect your investment with epcor

IATF 16949:2016 Certified

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WELCOME TO EPCOR FOUNDRY
Ready for a solid partner from launch to production on new and transfer projects

Program Management:

  • Advanced Product Quality Planning
  • Quality Certified to IATF 16949:2016
  • Full Engineering Resources
  • World Class Tooling and Casting Simulation

Our transparent launch operation keeps you informed so program management is one less thing you need to worry about.

IATF 16949:2016 Certified

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Stringent automotive expectations demand high level process controls –
Epcor brings these standards to all industries

We never stop producing quality components for you.

The importance of aluminum in automobiles and commercial vehicles is ever-increasing due to many industry advantages which include lighter weight, complexity and design flexibility. Regardless of your industry or product line, Epcor can offer you the standards you need from a supplier. Let us show you how!

IATF 16949:2016 Certified

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Do you have a supplier preventing you from meeting your customers orders?
We can help

  • Shortest production lead times to help you win new programs.
  • Maintain supply to your customers on current projects.
  • Absolute control of foundry tooling division to ensure seamless transfer tooling adaptation.

Please contact us to discuss your specific needs.

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INDUSTRY 4.0
Increase Productivity and Quality through innovations in technology.

Epcor Foundry is focused on technology, processes, procedures and systems that create castings that meet the highest standard of quality. Implementing automation makes better parts – a benefit you can count on.

EPCOR FOUNDRY AUTOMATED PROCESS CONTROLS

Robotics

Automated 5-Axis Robotic Sawing

  • For precision cutting

Robotic Pouring

  • For precise and consistent mold pouring

PLC based monitoring and control of the following processes:

Sand System: Screening, aeration and additions

  • For accurate repeatability

Sand Production: Continuous sand testing

  • For mold-to-mold conformity

Knockout: Job-specific pressure and and timing controls

  • For exact consistency

Shot blast: Part specific parameters

  • For spectacular finishing

Following best practices for implementing automation is something we take seriously at Epcor. Industry 4.0 is about using the internet of things to create new ways to do things more efficiently. When deployed correctly, automation reduces waste and increases quality

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Get the Quality You Expect From Epcor!

Epcor Is Opportunity

Questions about retooling or resourcing current aluminum casting programs?

Faced with complex aluminum casting challenges?

Please allow our team to help you develop the solution right for your company!

CONTACT US

CAPABILITIES

LEARN MORE

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IATF 16949:2016 CERTIFIED

VISION. TEAMWORK. UNITY. YOUR TRUSTED SOURCE FOR QUALITY

IATF 16949:2016 was published by the IATF and replaces the current ISO/TS 16949, defining the requirements of a quality management system for organizations in the automotive industry.

WHY THIS MATTERS
Achieving this level of certification means our customers are ensured that they are purchasing the highest quality parts from a manufacturer dedicated to defect prevention, reduction of variation, and waste in the automotive industry supply chain.

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When Hot and Cold Isn't Bad!

Pressure Tight/Leak Tight Requirements? Stringent Field Applications?
These are familiar terms in many US markets such as Heat Exchangers and Air/Fluid Filtration. Epcor is proud to be supporting numerous tier 1 and OEM customers on the most challenging casting applications in these segments

  • EXTENSIVE COMPREHENSION OF LEAK TIGHT requirements for air and fluid movement
  • IN-HOUSE CASTING SIMUALTION provides the best opportunity to minimize porosity and yield a solid casting
  • WE MANUFACTURE covers, oil/water cooler components and housings for critical industrial application

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We Wish You A wonderful Holiday Season!

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Diesel Engine Innovation Takes Epcor Foundry Into New Market Segments

Diesel engines have always been critical in the toughest heavy and long haul applications. Now, diesel engines are gaining increased interest for their improved carbon emissions and fuel efficiency making them a welcomed addition to passenger vehicle and light-duty platforms.

Epcor is proud to be a critical part of this picture supporting numerous Tier 1 and OEM customers on the most challenging casting applications in this arena.

  • LEAK TIGHT
    applications for air and fluid movement
  • WE MANUFACTURE
    turbo and supercharger components, manifold and inlet systems, oil/water cooler components and housings

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Let Epcor Foundry Be Part of the Building Blocks of Your Success!

  • Superior Tooling Designed and Built In-House
  • Three Generations of Tooling and Parts Making Experience
  • Shortest Lead Times in the Industry

Tell Us What You Need!

Epcor understands the key components of a successful operation. Partner with Epcor and see why we are
YOUR TRUSTED SOURCE FOR QUALITY

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Customers Come First at Epcor Foundry!

Now more than ever, customers require a casting supplier to:

  • Lower costs by reducing part complexity.
  • Provide the lowest total cost US-sourced castings.
  • Offer the best solution for shortest production readiness lead times to help you win new programs.
  • Maintain supply to your customers on current (transfer) projects.

We are here to help YOU!!

Please contact us to discuss your specific needs.

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We Turn Design Challenges into Opportunities

As an experienced global leader in aluminum casting technology – we've tackled the projects that others shy away from while maintaining quality

What is the Epcor Advantage?

  • Lower costs by reducing part complexity
  • Optimize process parameters utilizing simulation software
  • Provide the lowest total cost US sourced castings
  • Shortest production readiness lead times to help you win new programs
  • Work in conjunction with our sister company, Hitech Shapes Designs, to assure uninterrupted casting supply on transfer programs

Our precision craftmanship for complex and highly cored leak-tight aluminum castings gives you the competitive advantage you need.

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Tell Us About Your Casting Challenges.
We Have the Solutions.

While many of you are working from home, we are here to help you with your new casting designs. The Epcor engineering team is here to provide solutions for some of your toughest challenges. Whether you need a second look at a complex aluminum casting or are looking to redesign an existing part - we can help.

While businesses are being disrupted globally, we can help you make the most of a slower period.

American Made, Globally Trusted

Thank you for your business and partnership and we look forward to assisting you through these unprecedented times.

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CHARGING UP PRODUCTION

Epcor expands its production footprint in the Electric Vehicle segment. Let us work with you to expand your Electric Vehicle market share.


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AMERICAN MADE.
GLOBALLY TRUSTED.

At Epcor, we turn design challenges into opportunities. Our precision craftsmanship especially for complex and highly cored leak-tight aluminum castings is a skill that few can emulate. As we enter 2020, we will use our design and engineering skills to give you the competitive advantage you need for the highest performing aluminum parts.

We are your foundry of the future.

Happy New Year,
Dave Seilkop

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Midwest Design-2-Part Show

Visit Epcor Foundry & Seilkop Divisions at Booth #506

Midwest Design-2-Part Show
November 6 & 7, 2019
Indiana Convention Center • Indianapolis, IN

Free Registration: Click Here

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Transferred Tooling & On-Time Delivery is not an Oxymoron

Epcor has an exceptional history of maintaining casting supply when tooling is transferred to us. Our integrated quality driven processes include an in-house tooling facility and adapter plates which allow your patterns to seamlessly fit our machines.

Epcor Foundry is ready to help you maintain an uninterrupted supply of castings to keep your productions lines running. Our diverse background, years of experience in tooling transfers, and strong history of financial stability are here to support you.

  • In-House Tooling
  • Robotic Automation
  • High Speed Molding
  • DISA & Sinto Machines
  • CNC Finishing
  • Rapid Prototyping
  • ISO/IATF 16949:2006 Certified
  • Medium to High Volume Production

Stop accepting “firm maybes” from your current supplier regarding on-time deliveries.

When reliability counts, accept nothing less.

Epcor has an exceptional history of maintaining casting supply when tooling is transferred to us. Our integrated quality driven processes include an in-house tooling facility and adapter plates which allow your patterns to seamlessly fit our machines.

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Driving Production Forward With Advanced Technology to Deliver Highest Quality Castings

Challenge:
Designing a casting to meet your first time throughput requirements—out of the gate.

Process:
Epcor’s Engineering Team examines your casting with advanced simulation software to both guarantee results and craft out-of-the-box design solutions.

Result:
Shorter launch lead times, and better long-lasting casting.

Additionally, significant reductions in both internal scrap rates at Epcor Foundry as well as a reduction of external scrap at the customer are being realized.

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The Seal of Quality

Epcor is your team for fresh thinking. We challenge existing assumptions and then put our technology and processes to succeed where others fail.

Below is another example of our aluminum casting breakthroughs.

Challenge
OEM automotive company was plagued by housing components that failed due to leakage.

Epcor Solution
Step 1: We used simulation sofware to correct areas that had been causing problems.
Step 2: Our engineering team designed new tooling to cast a chill into the rotor core – allowing heavy sections to solidify without shrink prorosity.

Result:
Epcor eliminated leaking – 100%!

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Foundry Robotic Systems

The harsh work environment in the foundry is like no other. It is exactly that demanding environment that has positioned foundries to be on the leading edge of robotic automation.  All foundries contend with high temperatures and the inherent issues associated with pouring metal. Robots handle this in a repeatable fashion that makes the foundry more efficient, safer, and unfazed by the heat seen in production.

At Epcor, the benefits for adding robotic automation were considerable:

  • Improved uptime on the production line
  • Created a safer work environment
  • Unmatched pouring consistency and accuracy
  • Improved molding rates

Robotic automation also provides us with the flexibility to change – as your part requirements change.

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HAPPY NEW YEAR!

Now is a great time to look at bringing your castings back to the U.S.!

Have a question about reshoring aluminum casting work? Allow Epcor to show you our precision craftsmanship, especially for complex and highly cored leak-tight castings, used in several industries including automotive.

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We hope you have a wonderful Holiday Season!

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Epcor for Faster Casting Delivery

Todays customer expect programs to be launched faster than ever!
do you need castings sooner?

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WELCOME TO EPCOR FOUNDRY

When working with Epcor, you will experience a worry-free partnership from start to finish on new launches or transfer projects.

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Complex High-Performance Aluminum Castings for the Automotive Industry

As the number of automobiles increases, manufacturers of aluminum parts will be called upon to make more complex high-tech lightweight parts to increase safety and last longer. For this industry, aluminum builds better vehicles. The importance of aluminum in commercial vehicles and cars is increasing due to the many industry advantages. While most people emphasize the lightweight benefits for increasing fuel economy and reducing emissions, we like to also point out that castings made from aluminum can be amazingly complex while also being cost-effective, strong and very durable. Look for more aluminum in each vehicle in the future, including the structure.

Click Here to read the full article.

Click Here to download the PDF.

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THE POWER OF ONE

The highest quality for machined castings happens when precision processes are performed under one roof.

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Epcor Foundry announces National Sales Executive

Epcor Foundry, a division of Seilkop Industries, Inc., recently announced Jeffrey A. Miller as National Sales Executive, effective immediately.

For the past twenty-three years, Jeff Miller has held key management positions in casting and machining sales and is highly experienced working with our nation’s largest users of automotive and truck parts.

In this position, Miller will be responsible for account management, equipment quotations, and developing metal casting solutions.

“Jeff is a seasoned manufacturing and sales professional focused on developing successful aluminum casting solutions, especially for the transportation and truck industry. We look forward to his contributions and technical expertise to drive our Company’s goals into additional markets. We are pleased to have him onboard in this important position,” said David Seilkop, President of Epcor Foundry.

Miller is a graduate of Bowling Green State University with a bachelor’s degree in business.

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Lowest cost US Productions Source

American Made, Globally Trusted & Lowest cost
- Epcor Foundry is your low cost U.S. source and proud to be 100% designed, engineered, and manufactured in our Cincinnati, Ohio production facility.

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Prototyping-To-Cost Savings

Epcor's prototyping services lead to substantial cost savings. Read about our process to reduce prototype costs.

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Epcor's Unmatched Casting Quality

Read about Epcor's Preventative Maintenance (PM) program that focuses on prevention over detection.

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Supercharged Modern Muscle Cars

Read about how Epcor designed a better performing super light and leak-free casting for high performance automobiles.

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Automated Processes and Why They Matter

Read about how Epcor’s automated process control ensures castings are made of the highest quality.

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Get More Than Just the Best Aluminum Castings

Read about this Tier 1 automotive challenge that Epcor solved with a new gating system which eliminated leaks and scrap.

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This is an ideal time to reshore your castings!

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Epcor Foundry Installs Schaefer Furnace

Epcor Foundry, a division of Seilkop Industries recently installed a combination dry hearth and wet bath aluminum melting furnace from The Schaefer Group.

This gas fired furnace delivers degassed and filtered metal to the casting line – which gives Epcor the cleanest metal possible. The end opposite the dry hearth has a degassing unit and a filter with two electric elements in the ladle well end of the furnace, to maintain temperature stability during production.

"The Schaefer Combination Furnace gives Epcor the ability to produce higher quality parts more efficiently,” said Dave Seilkop, president of Epcor Foundry. “The unique ability of this energy saving combination furnace to also reduce metal loss with cleaner metal makes this an ideal choice for our aluminum part production,” he added. Installing the best equipment means producing better products at less cost for our customers – it's that simple!

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Accelerating Production Design, and Getting It Right

Like every “solution,” this one started with a problem. An unnamed foundry supplying exhaust gas recirculation (EGR) valves to an auto parts manufacturer could not fulfill the order, and that buyer urgently needed to find an alternative source for aluminum castings. Epcor Foundries in Cincinnati was awarded the business. Then, Epcor’s challenge was to get the new part into production quickly, avoiding the quality problems that the previous supplier faced.

Epcor used ESI Group’s QuikCast casting simulation software to evaluate the initial mold design. They were able to identify several areas where the simulation showed porosity would be a problem. Engineers ran a series of alternative mold solutions while adding risers to feed molten metal to compensate for shrinkage in critical areas of the mold.

Click Here to read the full article.

 

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