Offshore Die Casting

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Barron Industries is a long-established metal casting foundry serving clients in many industries. We’re committed to meeting and exceeding the expectations of the most demanding applications, delivering both the quantities and the quality our customers need. Our extensive range of quality certifications, including ISO 9001, AS9100, and NADCAP, speaks to this commitment.

In order to meet our customers’ high-volume casting needs, we have partnered with a carefully selected, world-leading, high-pressure die casting foundry in India. For over 20 years, Barron’s customers have benefited from our strategic alliance partnership to provide world-class aluminum die castings used in automotive and industrial applications.

Our offshore die casting partner is an industry leader who operates to our high standards. All die castings produced offshore are received in our Michigan facility and inspected by our employees before delivery. We also maintain levels of safety stock to prevent supply chain disruptions.

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High precision die mold for casting automotive aluminium parts make with iron metal steel by lathe milling drilling and CNC machinery in the factory

NADCAP – Nondestructive Testing • AS 9100 • ISO 9001 • ITAR Registered • SAM Registered • Certified Small Business

Cage code 7L135 – Primary NAICS: 331512, 331524, 331524, 331529, 332710

Capabilities

Our offshore die casting partner works with a range of aluminum alloys, can produce parts ranging from one to four pounds, and adheres to ISO 9001, ISO 14001, ISO 45001, and IATF 16949 standards. Additional services include CNC machining, coating, and testing.

Benefits

High-pressure die casting is a cost-effective process for producing high-volume parts in non-ferrous alloys. Its primary benefits include:

Near-Net Parts: Die casting provides complex shapes with closer tolerances than many other mass production processes and with low defect rates.
Secondary Machining Not Required: Little or no machining is required, and hundreds of thousands of identical castings can be produced before additional tooling is required.
Dimensional Stability: Die casting also produces lightweight, dimensionally stable, and durable parts while maintaining close tolerances.
Suitable for Thin Wall Parts: The process is suited for thin wall parts, which reduce the weight while maintaining strength.
No Joining or Fasteners: Die casting can also incorporate multiple components into one casting, eliminating the need for joining or fasteners. This means that the strength is that of the alloy rather than the joining process.
Multiple Finishing Techniques: Die cast parts can be produced with a smooth or textured surface, and they are easily plated or finished with minimal surface preparation.
Simplified Assembly: Die castings provide integral fastening elements, such as bosses and studs. Holes can be cored and made to tap drill sizes or external threads can be cast.
Exceptional Mechanical Properties: Die castings often have good corrosion and heat resistance, high thermal and electrical conductivity, and excellent strength at elevated temperatures.

The Process

The basis for the die casting process is using high pressure to inject liquid metal into a reusable steel die. There are some variations to the process, such as hot chamber die casting, cold chamber die casting, and structural (or high-integrity) die casting. The general process is as follows:

A die is made with tool steel and divided into two halves so the cast part can be ejected once the metal has solidified. The dies are usually cleaned and lubricated to ensure easy removal of the cast component.
Metal is heated up in a separate furnace and transferred to the casting machine, where the molten metal is injected into the die under high pressure, ensuring it fills completely before solidification begins. Die casting machines incorporate features to stop the high pressure forcing the dies apart. Additionally, die are engineered for high stiffness and rigidity, and manufacturers have a rigid clamping mechanism to hold the dies together during injection.
Once the metal cools and solidifies, the casting is removed from the die. Any excess material is trimmed off the casting.
Depending on surface finish requirements, the casted component may undergo other finishing processes, like sanding, grinding, or shot blasting.