Capabilities
Prototypes & tooling
Prototypes let you find problems early, test real parts and get UL testing started before you commit to production tooling. We work from standard CAD files (usually SolidWorks) and suggest changes that make the part easier to cast.
Our own process turns a 3D CAD file into a cast aluminum prototype that is about 95% production-accurate in roughly a week. For a production-accurate part, we work with partners to 3D print a sand pattern, typically in a few weeks.
What you learn from the prototypes goes straight into the tooling design, and first articles off production tooling can follow in under a month. We also run, repair and store customers’ existing patterns.
More capabilities
- Sand castingGreen sand for repeat parts and air-set (no-bake) for larger, complex or low-volume castings.
- Permanent moldGravity-fed die casting for repeat parts with tighter tolerances and a better finish than sand.
- CNC machiningIn-house CNC turning and milling, planned together with the casting.
- Heat treatmentCertified furnaces bring castings to the strength your print calls for, in-house.
- FinishingCastings cleaned, ground and blasted, ready for machining, coating or assembly.
Related reading
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 →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 →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 →
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