Mumford Metal Casting

Mumford Metal Casting — Aluminum and Zinc Die Casting

Our Collaboration with Customers is Well-Engineered

When you work with Mumford Metal Casting, we collaborate with you right from the start in the early stages of development to assist in the DFM (design for manufacturing) process and then work closely with you throughout every step of the launch process to production. In fact, we don’t just offer a design and engineering consultation, we insist upon it. That’s because this yields the highest level of quality and maximum value for you.

Our partnership with our customers also ensures we can optimize the compatibility of our production processes and alloys with your product and parts requirements. This philosophy of continuous quality improvement begins with the review of casting design by anticipating potential non-conformance and “building in” preventative action including appropriate monitoring of critical process characteristics. From weight savings to mold flow, we bring creative solutions to your project – on time and in budget – for today’s evolving marketplace.

Automation

At the Mumford Metal Casting headquarters, we have a robotics laboratory where equipment used throughout our locations are set up and configured, to ensure accuracy, efficiency allowing us to stay updated with changing technology. The latest technology including robotics in our fully automated die casting/machine cells allows us to be highly competitive on high-volume projects.

At Mumford Metal Casting we utilize automation in all of our high-production high-pressure die casting facilities achieving the benefits of both ergonomics and safety for our employees and also providing a stable, consistent and efficient manufacturing process.

At our Dowagiac, MI facility, we offer an automated cell that incorporates a machining process. This is unique in that the gates, runners and biscuit are left on the part, and the robot guides the parts though quench, drill/tap machining operation, and final trim to remove the gates, runners and biscuit. The automatic trim ejects the parts onto the table that delivers them to the operator to inspect and pack. This automated process is far more streamlined and efficient because only one operator is needed for the cast, machine, inspect and pack operation. This robotic, machined approach also provides a significant advantage in security. The parts cannot even reach the operator unless all the secondary operations beyond casting are completed, ensuring a higher quality result for our customer.

View our fully automated cell:

Simulations

Mumford Metal Casting utilizes EKKcapcast which is software that is both powerful and flexible, and capable of simulating every casting approach. The entire process, whether high-pressure die casting or gravity casting, can be simulated from start to finish. In die casting, complete runner systems can be designed, a stress analysis can be performed on the mold and casting, and even problematic flow patterns can be diagnosed. For sand casting, real-time observations of temperature on solidification patterns can be observed. Simulation can improve yields and reduce costs by helping avoid physical mold alterations. Development lead times can be reduced by fine tuning the design virtually before cutting the mold.

EKKcapcast simulation software provides superb benefits for: high-pressure die casting, low-pressure processes, semi-solid Thixomolding, permanent and semi-permanent molding, squeeze casting, green sand casting, hard sand casting, precision sand casting, centrifugal casting and structural investment casting.

Simulation Videos

Die Cast > Permanent Mold > Sand Cast >

CAD

All Mumford Metal Casting manufacturing facilities have 3D SOLIDWORKS® CAD capabilities. The powerful functionality of this platform can shorten product development time, helps reduce costs and contributes to improved quality which is another way that MMC maintains our commitment to the highest standards. The dedicated tools and workflows of SOLIDWORKS streamline the design from concept to manufactured product. Rapid design changes are easily made and visualized, from simple designs to complex configurations, keeping your ideal product on the desired timetable.

3D Printing and Scanning

Mumford Metal Casting brings capabilities in 3D printing for rapid prototype development, as well as 3D scanning for large castings. Our 3D printing machine first creates a plastic prototype which is then assessed, revised if needed, and verified in order to create the 3D casting part in the appropriate metal alloy. The 3D printed part can then be used to develop a sand cast pattern to produce a part in non-ferrous alloy. Mumford Metal Casting has a proven track record of innovation employing such advanced approaches as 3D printed tooling which can contribute to better cooling, reduced cycle time and longer tool life. This newer technology may be particularly appropriate for free-form designs that are often more difficult to create using traditional machining processes. Mumford Metal Casting employs 3D scanning for purposes of reverse engineering products, measuring mold surfaces as well as measurement of complex-shaped parts.