Insights
Straight answers on casting and sourcing.
Practical articles on processes, tooling, cost and lead time, written for the people who buy and design cast parts.
The Certain Benefits of Prototype Casting
Designers/engineers can gain tangible proof of the component's quality, find unexpected flaws and perform testing that delivers invaluable data. Marketers can use prototypes to gain feedback from customers or investors before full-scale production begins.
Read the article →Metal Casting Defects
Casting defects occur due to defective pattern design, improper melting of metal, defective molding material, or improper venting. Defects can also occur due to control limitations or human interference.
Read the article →5 World-Changing Metal Applications
Five non-ferrous metal applications which affected global industries in a big way include aluminum aircraft frames, magnesium transmissions, titanium golf clubs, zinc electrical hardware, and bronze gears.
Read the article →What Is The Metal Solidification Process?
Different casting methods employ various equipment and techniques, all methods observe the metal solidification process. It takes an experienced and skilled foundry to control this process and avoid casting defects that result from improper handling of the solidification process.
Read the article →Metal Sand Casting Process—Step-by-Step
Precision Sand Casting in 6 Steps. Sand casting is pouring molten metal into a sand mold; the metal then solidifies to fill the shape of the mold. While proper equipment and experience are required to produce a casting free of defects, the sand casting process itself is pretty simple.
Read the article →3 Types of Sand Casting
Over 70% of the world’s metal castings are produced via the sand-casting process. Sand casting is highly efficient and cost-effective.
Read the article →What Is An Alloy
A metal alloy tends to be harder/stronger and more durable than pure metal because the mixture has atoms of different sizes. Alloys also provide resistance to corrosive environments and can improve appearance of products, as they are lustrous and contain a better finish.
Read the article →A Guide To Non-ferrous Metal Alloy Casting
Metal casting is a complicated process that involves pouring liquid metal into a mold, allowing it to cool, and then extracting the product. Depending on the metal used and the required outcome, we utilize sand casting or permanent mold casting to create prototypes and products. Non-ferrous sand casting is highly efficient and cost-effective. Permanent mold utilizes gravity when pouring molten aluminum into molds (or dies) machined from cast iron or steel. Ermak takes pride in producing high-quality castings that are consistent, repeatable, and cost-effective. We customize the casting process to meet your needs using the best, most efficient non-ferrous metal casting process for your product.
Read the article →Rapid Prototyping
Ermak can make prototype castings in many different ways, typically with fast turnaround times and substantially lower cost than sample machined parts.
Read the article →When to use castings vs. machining
When does it make sense for a part to be a casting versus a machined or fabricated part? Identifying complex parts or parts that waste raw materials is an easy first step to determine a good candidate for conversion.
Read the article →How to relocate from a domestic foundry
Would you like to explore moving your part or product between foundries but have no idea how to do it? The simple answer is that as long as there is a detailed process to follow and frequent communication between the customer and the foundry, transitions are relatively straightforward before we get into how. Let's start with some common themes we see.
Read the article →Reshore-Broken Supply Chains
The most frequent reasons for reshoring are shorter lead times, lower minimum quantities, higher quality products, concerns over products being copied/sold, and more assurances in raw materials used.
Read the article →Why Aluminum?
Aluminum applications span from everyday items like fuel-efficient vehicles to smart phones to window frames to airplanes. It has a long list of inherent assets that makes it referred to as a “miracle metal” – lightweight, corrosion resistant, easily formed, highly conductive, highly reflective, non-toxic, durable and recyclable – and gives manufacturers and designers a wide range of options for product innovation and process improvements.
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