Eagle Group Blog | Metalcasting

    Coming Soon: AFS Regional Student Casting Competition

    Posted by Jeff Cook on 2019 Jan 28

    Forget about the Rose Bowl–this year's college competition to watch is coming up in February!

    The AFS Wisconsin Regional Invitational Casting Competition will host casting teams from colleges and universities around the Midwest. Taking place during the AFS Wisconsin Regional Expo and Conference, the event invites student teams to present cast products they've created using school casting facilities. All projects in competition were completed by members of AFS student chapters.

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    Tags: Metalcasting, Students, Student Metalcasting Competition

    Introduction to Greensand Casting

    Posted by Jim Smith, Jr. on 2019 Jan 22

    Greensand casting is a time-tested and highly versatile metalcasting process. Different foundries use different methods and materials, but greensand casting always involves creating molds by compacting moist, organically bonded sand around patterns. Whereas shell molding uses heat-bonded sand and no-bake casting uses chemically bonded sand to form molds, greensand casting is unique in that sand is bonded through naturally occurring compounds–in most cases, the bonding agent is clay.

    At Eagle Aluminum Cast Products, our two principle casting methods are greensand and permanent molding. The greensand process is very customizable and capable of manufacturing nearly any type of cast product. Here, we'll explore the processes, casting characteristics, benefits and challenges of the greensand casting process.

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    Tags: Metalcasting, Processes, Eagle Aluminum, Greensand Casting

    Manufacturing Day 2018 at Eagle Alloy: Event Recap

    Posted by Jeff Cook on 2018 Oct 11

    Eagle Alloy was lively and bustling on Thursday, October 4th. That's no surprise: our Muskegon, MI campus is regularly buzzing through three shifts a day, five days a week. But this particular day brought in a larger crowd than usual: in celebration of Manufacturing Day 2018 we opened our campus to local schools and community representatives for a demonstration of modern metalcasting.

    The goal of Manufacturing Day is to inspire the next generation of manufacturers, and we wanted to support that goal any way we could. By inviting students to witness our work firsthand, we aimed to provide an introduction to modern metalcasting and manufacturing. After nearly 40 years in business, we understand the importance of letting young people know about the exciting potential of metalcasting careers.

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    Tags: Metalcasting, Education, Community, Manufacturing Day, Event

    Getting Started with the Eagle Group: What You Need to Know

    Posted by Vikki Shonkwiler on 2018 Aug 16

    The Eagle Group is comprised of four companies: a shell molding foundry, an aluminum casting foundry, an investment casting foundry and a CNC machine house. Together, we're able to manufacture a broad range of metal products from concept to completion.

    If you're looking for a new supplier for your raw or machined cast products, the Eagle Group could be the perfect fit. We pride ourselves on customer satisfaction, continuous improvement and outstanding work during all phases of the production process.

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    Tags: Metalcasting, Manufacturing, Product Design, Development, Capabilities, Product Development

    Getting Started with Permanent Mold Casting

    Posted by Jim Smith, Jr. on 2018 Jun 27

    Permanent mold casting is a type of metal casting involving reusable molds. Whereas other casting methods, like sand casting and investment casting, use disposable molds, permanent molds last much longer and can be used to produce hundreds, or even thousands, of identical parts.

    Every project can be matched with the ideal casting method. For non-ferrous castings with medium-to-high volumes, permanent mold casting offers a long list of advantages.

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    Tags: Metalcasting, Aluminum Casting, Eagle Aluminum, Permanent Mold Casting

    Getting Started with Airset Casting

    Posted by Jeff Cook on 2018 Jun 7

    Every manufacturer bringing a cast product to market must decide on the right casting process to use. Casting methods like shell molding, greensand casting, investment casting and airset casting all have their own sets of benefits and drawbacks. The right choice depends on the quantity being cast, the size of the part, and the requirements for dimensional accuracy, surface finish and material.

    While it's not as widely used as shell molding or greensand casting, airset casting has plenty of advantages, and can be the perfect option for the right product.

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    Tags: Metalcasting, Eagle Alloy, Airset Casting

    How Investment Casting Compares to Other MetalCasting Methods

    Posted by Deb Pipoly on 2018 May 8

    All metal casting processes have their own unique characteristics. When designing a new part for casting, the most appropriate process should be determined by a number of factors, including:

    • Tooling costs
    • Labor costs
    • Design characteristics
    • Desired appearance

    The goal of the manufacturer and the supplier should be to find the optimal balance that produces the lowest per-part cost at a given quantity, while meeting or exceeding all quality requirements.

    Here, we compare investment casting to three metal casting processes: shell mold casting, greensand casting and permanent mold casting.

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    Tags: Metalcasting, Processes, Investment Casting

    Aluminum Casting vs. Steel Casting: Choosing the Right Alloy for Your Cast products

    Posted by Jim Smith, Jr. on 2018 May 1

    In modern metal casting, steel and aluminum are two contenders for the top choice. Thousands of manufacturers around the world rely on both metals to produce strong, light and corrosion-resistant metal parts and products.

    You'll find hundreds of different grades and alloys for both steel and aluminum, and each has its specific advantages and disadvantages. For this comparison, we'll focus on differences between aluminum and steel alloys in general, rather than zooming in on differences between specific alloys.

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    Tags: Metalcasting, Machining, Aluminum Casting, Aluminum, Materials

    Investment Casting Guide Ebook: New Eagle Group Resource for Manufacturers

    Posted by Deb Pipoly on 2018 Apr 18

    Eagle Precision Cast Parts, Inc. just released a downloadable resource, titled Investment Casting Process Guide: A Comprehensive Introduction to Investment Casting.

    The goal of the 21-page ebook is to make it easy for manufacturers, and anyone else who's interested, to learn the basics of investment casting. Manufacturers looking for a better way to produce parts can find information on tolerances, design recommendations and a full case study.

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    Tags: Metalcasting, Investment Casting, Eagle Precision, Investment Casting Guide

    5 Mistakes Companies Make When Choosing a New Metal Casting Supplier

    Posted by Jeff Cook on 2018 Apr 17

    Whether you're bringing a new product to market, improving on an old design or entering the world of metal manufacturing for the first time, you'll need to find the right foundry for the job. Choosing a metal casting supplier can be a daunting task, and not everyone makes the right choice the first time.

    These five mistakes companies make when choosing a new metal casting supplier can lead to expensive fixes, defective products, overpriced castings, logistical headaches and customer service nightmares. Read on to find out what NOT to do when choosing a new foundry.

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    Tags: Metalcasting, Supply chain, Suppliers

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