CAPABILITIES
At Hawver Aluminum we offer a wide range of capabilities in order to provide customers with options that suit their needs. From age old Green Sand Molding to advanced 3d Printed mold and core assemblies. We can also aid in casting development, assembly, and a range of other services. With our decades of experience in the industry and our evolving set of services and technology, we help businesses obtain the castings they need, and help eliminate the hindrances that can prevent a problem free manufacturing experience.
Green Sand Molding
Green sand molding uses a mixture of sand, clay, and water that is able to be compacted within a frame called a flask, onto a pattern in order to create a hollow cavity matching the part to be produced. The mold consists of 2 halves, the cope (upper) and drag (lower). A sand core may be placed inside to create a hollow part, or to create details that would be difficult to produce in a typical cope and drag setup.
We utilize jolt squeeze and rotolift molding machines to produce parts ranging from several ounces to roughly 50lbs, depending on part shape and specifications. This is the faster of our processes, suitable for relatively straightforward designs. For larger or more complex castings we use one of the processes below.
No Bake (Air Set)
No Bake (Air Set), uses a dry sand mixed with a two part binder to produce a very strong mold with a higher quality surface finish compared with green sand. This added strength and ability to reproduce more detail from the pattern make it an excellent option for larger and more complex castings. We are able to cast accurate parts with this system from several ounces to over 600lbs.
No Bake (Air Set)
No Bake (Air Set), uses a dry sand mixed with a two part binder to produce a very strong mold with a higher quality surface finish compared with green sand. This added strength and ability to reproduce more detail from the pattern make it an excellent option for larger and more complex castings. We are able to cast accurate parts with this system from several ounces to over 600lbs.
3d Printed Molds
3d printed molds work in the same basic fashion as other 3d printed products. A CAD file is used to program the printer to produce a mold in layers with resin bonded sand. Once the mold is cleaned and assembled it can be poured with aluminum to create an aluminum casting. We mainly recommend this process for prototyping, when the customer needs a finished part in order to finalize their design. Once the design is finalized, production runs would be set up for either green sand or no bake. Other uses would be for one off parts, very small runs, and very complex designs that our other processes wouldn't be suitable for.
3d Printed Molds
3d printed molds work in the same basic fashion as other 3d printed products. A CAD file is used to program the printer to produce a mold in layers with resin bonded sand. Once the mold is cleaned and assembled it can be poured with aluminum to create an aluminum casting. We mainly recommend this process for prototyping, when the customer needs a finished part in order to finalize their design. Once the design is finalized, production runs would be set up for either green sand or no bake. Other uses would be for one off parts, very small runs, and very complex designs that our other processes wouldn't be suitable for.
CORES
Shell
Cores
Shell cores use a heat activated, resin coated sand to make cores with an excellent surface finish, and are quick to produce when compared with No Bake. These cores are made in a machined aluminum corebox, which is more costly to set up than No Bake, but offer a lower cost to produce and the ability to make large numbers in a shorter amount of time. These are recommended for higher volume products, and pair well with green sand molds.
3d Printed
Cores
Made in the same way as 3d printed molds, these cores are often used when changes may still need to be made to the design of the casting. No tooling is required, so changes can be made without the expense of altering or remaking tooling. Some parts with intricate designs may use these in full production, when standard core making processes are too complicated or problematic to be utilized.
3d Printed
Cores
Made in the same way as 3d printed molds, these cores are often used when changes may still need to be made to the design of the casting. No tooling is required, so changes can be made without the expense of altering or remaking tooling. Some parts with intricate designs may use these in full production, when standard core making processes are too complicated or problematic to be utilized.
No Bake
Cores
3d printed molds work in the same basic fashion as other 3d printed products. A CAD file is used to program the printer to produce a mold in layers with resin bonded sand. Once the mold is cleaned and assembled it can be poured with aluminum to create an aluminum casting. We mainly recommend this process for prototyping, when the customer needs a finished part in order to finalize their design. Once the design is finalized, production runs would be set up for either green sand or no bake. Other uses would be for one off parts, very small runs, and very complex designs that our other processes wouldn't be suitable for.
No Bake
Cores
3d printed molds work in the same basic fashion as other 3d printed products. A CAD file is used to program the printer to produce a mold in layers with resin bonded sand. Once the mold is cleaned and assembled it can be poured with aluminum to create an aluminum casting. We mainly recommend this process for prototyping, when the customer needs a finished part in order to finalize their design. Once the design is finalized, production runs would be set up for either green sand or no bake. Other uses would be for one off parts, very small runs, and very complex designs that our other processes wouldn't be suitable for.
Alloys
The two main alloys we use in our facility are A356 and 535 Almag.
We recommend A356 for general use as it has well rounded mechanical properties, and can be heat treated for additional strength. We recommend Almag for marine use and specialty applications. It has very good corrosion resistance, high strength and elongation, without heat treating.
Heat Treat
We have heat treating capabilities for parts requiring high strength and better machineability or for stress relief and dimensional stability. A356 gains a substantial increase in strength when taken to the t6 temper, as well as becoming much more suitable for machining.
Brinell Hardness Testing
Parts run through our heat treat process are hardness tested to ensure the correct temper and machineability.
Prototype Castings
With our years of experience casting quality aluminum castings we can aid in product design and prototyping. Once finalized we can begin full production to supply you with the castings to help meet the demand for your new product.
Finishing
After the castings are removed from the molds they are cut from the runners, the gating and any flashing or burrs are ground away, shot blasted to provide a uniform finish, and inspected before being prepared for shipment.
Assembly
We offer assembly services for some products that utilize our castings, providing you with a finished product that is ready for sale. Alternately we can help you develop your own assembly process if you prefer to assemble in house.
CNC Machining
We can provide basic machining, such as drilling and tapping at our facility. For more complex cnc machining we can save you time and hassle by shipping parts directly to your machine shop, or we can recommend a shop that we have done business with.
Powder Coating
As with cnc machining, we do not provide powder coating in house, but are happy to ship parts directly to your powder coater, or one that we recommend.
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