Brukar Inc. manufactures consistent high-quality sand castings for OEMs throughout North America and Europe. Diversification is the key to Brukar’s flexibility, Green Sand Moulding, air-set sand moulding processes are utilized to produce the highest quality castings.  Sand Casting is very versatile and cost effective process, it can produce parts of a large variety of complexity and size, ranging from a few ounces, to several tons.  Complex or simple cores can be designed and placed to create simple or complex internal Features.  Post process machining and surface finishing produce parts that meet the needs of many of Brukar’s customers.

Sand Casting Capabilities

• Induction Furnace with crucibles of 330lbs to 660lbs (150kg to 300kg)
• As cast dimensional tolerances: ISO 8062-4:2017
• As cast surface quality standard: MSS SP-55-2011
• Size Range 1.1lbs to 2200 lbs, (0.5kg to 1000kg)
• Types of Sands: Green Sand & Air Set Sand
• Core Materials Available: No Bake Sand, Zicorn and Ceramic
• Point of use packaging to suit your production requirements
• Testing Facilities: spectrometer, tensile test machine, hardness test machine, CMM Dimension report
• Certifications: ISO9001:2008
• Machine Capabilites: CNC Turning, Milling, Drilling, Grinding, Cutting, Reaming and Threat

Shell Molding is also known as shell-mold casting. This process is known as an expendable mold casting that uses resin covered sand to make the mold. This process has great dimensional accuracy, and a high productivity rate. Generally, this casting process is used to make small to medium size parts that require high precision.

Shell Mold Castings use ferrous and non-ferrous metals, more common metals include, cast iron, aluminum and copper alloys, alloy steel and stainless steel. Parts that use the shell mold casting process tend to require high accuracy.

The permanent mould casting process, commonly known as gravity die casting, involved the production of castings by pouring molten metal into permanent metal moulds under gravity, low pressure, or centrifugal pressure.  With permanent mould castings, higher production rates can be achieved than with sand castings, but the single mould process is slower than high pressure die casting.  Sand cores are regularly used to allow more detail to be cast into the cast component needed.  The chill effect the mould has on the material poured improves the soundness and grain structure with better strength properties of the castings allowing thinner walls with dimensional accuracy to be designed into the component.

Common materials used for this process include, aluminum alloys, and zinc.  Iron and Steel alloys can be cast using a graphite mould.

Tolerance details:

• Casting Tolerances: +/-0.015 inches (+/- 0.381mm) for every 1 inch (25.4 mm) Add +/- 0.002 inches (0.0508mm) per inch (mm)
• Parting Line Shift: +/- 0.010 inches (+/- 0.252mm) to 0.030 inches (0.762mm)
• Minimum Section Wall Thickness: Average: 0.187 inches / 4.75mm
• Minimum Draft Required: 2° to 4°
• Surface Finish: 150 RMS to 300 RM

Die Casting is a metal casting process characterized by forcing molten metal under high pressure into a mould cavity.  All of Brukar’s die cast parts are cast using non-ferrous metals, such as zinc, copper, aluminum, and tin alloys.  The die cast process is especially suited for high volume production runes of small to medium sized components.

Dimensional consistency, superb surface finishes and dimensional consistency are among the most important factors when deciding on a casting process.  Brukar has been producing consistent, high quality die casted components for our OEM clients for the last three decades.

NADCA (North American Die Casting Association) Standards for Material, Design Criteria and Tooling for Die Casting apply.

Design Criteria

• As cast tolerance as tight as +/-.005″, post machining available for tighter tolerance applications
• Standard tolerance of =/-.10″ for the first inch and +/-.002″ each additional inch
• Typical surface finish of Ra 63-125 micro-inch as cast, post machining available for higher quality finishes
• Minimum draft = .5 degrees
• Minimum wall thickness = .030″ (Thinner wall thickness possible with alternative processes)

Brukar Inc. manufactures prototype, low volume, and production die cast tooling.  Our experienced suppliers, skilled team of CAD/CAM engineers and tooling professionals deliver quality tooling solutions for today’s demanding manufacturing environment.