Since 1983, Barron Industries has been committed to providing high-quality ferrous and non-ferrous precision investment castings. An industry leader, Barron was one of the first investment casting manufacturers to receive AS9100 Quality Certification in 2014. Barron’s full-service manufacturing process includes everything from design for manufacturing to in-house casting, CNC machining, NDT, and welding. Our vertically integrated manufacturing process significantly reduces cost and lead times without sacrificing quality. With our additive manufacturing techniques, we can produce a completely machined rapid prototype casting in as little as ten days.
Barron also offers complete supply chain management including redundant manufacturing, inventory management, low-cost, off-shore investment casting, and multiple casting processes. Barron provides both domestic and off-shore investment casting production in India. We can create two identical sets of tooling and use one set to produce parts at our Michigan location and the other at our India plant. With production at our Michigan facilities, Barron can provide prototype and low-volume investment castings quickly. For high-volume castings, the entire production process is developed in the US allowing compressed delivery time and production launch at our India plant.
Barron’s skilled technicians use advanced tools and technology to ensure that our investment cast components meet customer needs and applicable industry standards. Typically a linear tolerance of +/-.005inch/inch is standard for investment casting although it varies depending on the size and complexity of the part. The standard surface finish for our castings is a 125 to 150 rms microfinish.
ensures consistency in shell dipping, coating, and formation as well as enhanced efficiency in drying of ceramic shells. This means more consistent high quality castings being delivered to our customers.
includes three steel and two aluminum melting units, two ovens for wax burnout from the ceramic mold and four ovens for preheating ceramic shells. Redundant equipment ensure your castings will continue being processed, even if a piece of equipment breaks down.
Working closely with our OEM customers to reduce costs and lead time. Barron Industries was a pioneer in the use of ceramic shelling core technology. Our research and development reduced manufacturing costs by 20% through reductions in material waste and machining operations.
(MRP/ERP) software provides operational intelligence allowing continuous improvement, accountability, quality, and transparency throughout the investment casting process.
Utilizing the lost-wax investment casting process, Barron Industries produces both ferrous and non-ferrous precision castings from 2 oz to 250 lbs.
Barron is uniquely capable of delivering larger metal castings up to 25 inches or 63.5cm and 150 lbs or 68 kg for steel and 50 lbs or 22.7 kg for aluminum parts. Plus, we routinely produce cast alloy components with complex shapes requiring only minimal surface finishing or machining for completion.
With the precision lost-wax investment casting process, we can produce parts with strict tolerance requirements. Barron uses Solidification Modeling software to predict the outcome of a casting’s internal quality level before a part is ever made, significantly improving time-to-market and reducing development costs due to “trial and error” methods of process development. We are experts in value engineering for our customers. Barron will help you reduce weight, lead-time and cost, as well as improve the functionality of your part. Let us redesign or convert your costly multi-piece weldment or fabrication into a single-piece precision investment casting.
The Barron Industries investment casting process provides distinctive advantages over sand and other casting methods. Our precision lost wax casting method turns out high strength castings with greater dimensional accuracy, higher consistency, superior product integrity and improved surface finish. We frequently participate in up-front design with our customers to ensure manufacturability and the lowest cost design while maintaining critical machining tolerances.
Wax patterns are typically made by injecting wax into a metal tool or “die”. Since 1994, Barron has also produced patterns through 3D printing technology. Today, Barron can produce rapid prototype castings from most 3D printed materials including those used in FDM, SLA and SLS equipment.
It is typically uneconomical to make small parts one at a time, so wax patterns are attached to a wax “sprue”. The sprue serves two purposes:
The next step in the process is to build a ceramic shell around the wax tree. This shell will eventually become the mold in which metal is poured. To build the shell, the tree is dipped into a ceramic bath or “slurry”. Barron’s six-axis dipping robot ensures consistency and uniformity of shell production in intricate and complex parts. After dipping, fine sand or “stucco” is applied to the wet surface. The mold is allowed to dry, and the process is repeated a number of times until a layered (or laminated) ceramic mold, capable of withstanding the stresses of the casting process, has been built.
Before pouring metal into the mold, the wax is removed using a flash fire oven, which melts and burns off the wax. Flash fire burns off residual wax and cures the shell, readying it for casting.
Before the metal is poured into the ceramic mold or “shell”, the mold is preheated to a specific temperature to prevent the molten alloy from solidifying or “freezing off” before the entire mold is filled.
Alloy is melted in a ceramic crucible using a process known as induction melting. A high frequency electric current creates a magnetic field around the alloy, generating electric fields inside the metal (eddy currents). The eddy currents heat the alloy due to the material’s electrical resistance. When the alloy reaches its specified temperature, it is poured into the mold, and the mold is allowed to cool.
Once the parts are removed from the sprue, and the gates removed, the surface can be finished in a number of ways: