DIE CASTING PLAYERS IN USA

Ryobi Die Casting

Sales Volume: $150 - $200 Million

End Markets: Auto & Trucks, Lawn & Garden Equipment, Consumer Appliances, Electrical, Lighting & Wiring Devices, Electronic Equipment etc.

Capabilities
2 die casting plants and a machining facility encompassing 560,000 sq. feet of manufacturing space. Products include transmission cases, housings, engine parts, and most recently, structural parts. In addition, the company also manufactures smaller parts for Tuff Torq Corporation, which are utilized in the lawn and garden industry. The companys die cast machine sizes range from 500T 3500 Tons and the casting weights range from .0013 metric tonnes to .0181 metric tonnes. Their product range varies from small ladder brackets to large transmission cases and engine blocks. Melting over 77100.7 metric tonnes of aluminium per year and service some of the worlds top automotive manufacturers. Ryobi uses concurrent engineering practices and gets involved at the design phase to assure a very good PPM (Parts Per Million) and cost benefit to the customer for the life of the program. Notable clients include Ford, GM, Honda, Nissan and Toyota Ryobi has an on site preventive die maintenance team that responds quickly to any situation (24 hour/day).

Quality Assurance CMM (Capability Maturity Model) dimensional audit checks Computer generated SPC from CMM data Machining X-Ray and Machining audit check for porosity In-Process check L.A.S.T. policy (Look - Advise - Segregate - Take Action) Layered audit

Empire Die Casting

Sales in:

1. 2012: $40 million 2. 2013 $50 million

3. 2014: $60 million (Projected and based on order book) End Markets: Aerospace, Automotive, Defence, Food Processing, Medical Equipment, Sports and
Recreation, Power Tools, Pump and Valves, Lawn and Garden Equipment, Home Appliances.

Capabilities
Main products include Recreation Medical Supplies, Business Machines, Government Appliances Lawn / Garden Pumps / Valves 2nd / 3rd Tier Auto Electric Instruments Heavy Trucking, Hand Powered Tools, Mechanical Devices. Aluminium and Zinc Die Casting. Secondary capacities include Machining Assembly / Testing Shot Blasting Vibratory and Parts Washing. The company also has added value capabilities which include machining, secondary finishing and a tool and die shop. Engineering resources include design tooling, manufacturing support and repair/service in the formal engineering departments and also use special engineering tools such as Magma Flow Simulation. The company has in-house and outsourced model shop and prototype capabilities.

Quality Assurance
The requirements/specifications are communicated to suppliers via purchase orders and blue prints. The company measures quality with the help of customer surveys, customer complaints and company goals. Die casting process is monitored through Visi-Trak shot monitoring system. Quality inspection sheets are utilized by floor inspectors. Inspection capabilities include: 1. Incoming Inspection 2. FAI 3. In Process Inspection 4. Final Inspection 5. Layout Capabilities

Callen Die Casting LLC

Sales Volume: Under $10 Million End Markets:

In the aluminium die casting segments the markets served include off-road equipment, automotive sector, computer hardware, telecom, industrial lighting etc. In the zinc die-casting segment the markets served are metering and control devices, commercial lighting, lawn and garden etc.

Capabilities
Modern Aluminum Die Casting Machines ranging in size from 600 N.T. to 1750 N.T. produce complex castings for a broad variety of industrial market sectors Versatile range of Aluminum Die Castings weighing from a few ounces through 0.0158 metric tonnes are produced in volume. Vacuum-aided Die Casting is facilitated utilizing a unique Callen designed and manufactured hard-piped central vacuum system which is accessible at each casting machine via quick-connection. Complex thin-walled, low porosity Aluminum Die Castings are produced from the combined benefits of vacuum-aided casting and electronic process monitoring. The companys conventional Zinc die castings range in size from a few ounces to .005 metric tonnes and are manufactured in 0.2267 metric tonnes and 250 ton hot-chambered die casting machines. The value added operations (In House) of the company include 1. Vibratory Furnishing 2. Machining 3. Assembly Sub-Contracted Processes include: 1. Dichromate Coatings 2. Thermal Deburring 3. Plating

Quality Assurance
The company has various systems intact for the assurance of quality such as: Gauge Calibration Software In - Process Inspection System Capability Study Software Corrective Action System Optical Emission Spectroscopy

Pacific Die Casting Company

Sales: Under $10 million End Markets: Aircraft, Aerospace & Military, Auto & Trucks, Computer, ConsumerAppliances, Consumer Products, Defence, Electrical Equipment, Electrical, Lighting & Wiring Devices,Electronic,Engines & Turbines - Non-Automotive, Industrial Equipment & Machinery, Medical, Dental & Safety Equipment.

Capabilities
Aluminium die castings are made from machines rated from 150 to 600 ton machines. Turnkey services include: CMM first Article and production inspection, CNC production machining, shot blasting, vibratory finishing, and thermal deburring.\ Machining Operations: Boring, Burnishing, CNC ,Drilling, Reaming, Sanding, Tapping and Turning. Finishing Operations: Anodizing, Buffing, Chromating, Deburring, Painting, Plating, Polishing, Pressure Testing, Shot blasting, Powder Coating.

Quality Assurance
The company provides training in the use of quality tools, such as SPC, FMEA and specific customer QA needs.

General Die-Casters Incorporated

Sales Volume: $10 - $20 Million End Markets: Aircraft, Aerospace & Military, Auto & Truck (Body & Suspension), Commercial
Equipment & Products, Consumer Appliances, Electrical, Lighting & Wiring Devices, Electronic Equipment, Farm, Construction & Mining Equipment, Hardware Architectural, Fasteners, Hydraulic & Pneumatic Equipment, Industrial Equipment & Machinery. Instruments, Controls, Lab & Photo Equipment, Lawn & Garden Equipment. Motors, Fans & Generators. Plumbing, Valves, Environmental & HVAC. Power & Hand Tools, Pumps & Compressors, Recreational Transportation Equipment, Transportation (Non-Automotive)

Capabilities:
Capacities for aluminium die casting up to .009 metric tonnes. Capacities for zinc die casting up to .0036 metric tonnes.

Quality Assurance
Specroschemical Metal Analysis System Micro VU Optical Comparator Real Time X-Ray System Wilson Rockwell Tester Plant Wide Quality Computer System Zontec-SPC Data Collection System

 Soldy Manufacturing Company

Sales Volume: $20 - $30 Million End Markets: Appliance, Automotive, Commercial Equipment & Products, Computer, Consumer Appliances, Defence, Electronic, Electronic Equipment, Hardware, Industrial Equipment & Machinery, Lawn & Garden Equipment, Power & Hand Tools, Recreational Transportation Equipment. Capabilities Capable of casting: Up to .011 metric tonnes aluminium die castings, high speed miniature zinc die castings, as well as conventional zinc and aluminium with real time shot monitoring. Full secondary operation centre equipped with CNC machining, light assemble, vibrodeburring, and everything needed to supply a high quality aluminium and zinc die casting. The company has 25 hot (zinc) and cold (aluminium) chamber die cast machines. The equipment ranges from one ton miniature zinc die cast machines up to 1000 ton cold chamber aluminium die cast machines.

Quality Assurance Facilities for quality assurance include: X-Ray Analysis Mitutoyo Profile Projector Mahr Surface Profile Metallurgical Lab Analysis Compression Testing Functionality and Leak Testing

RCM Industries Inc

Sales Volume: $30 - $40 Million

End Markets: Auto & Truck - Please Classify. Commercial Equipment & Products. Consumer Appliances. Consumer - Other Products. Engines - Marine & Outboard. Hardware - Architectural, Fasteners, Other. Lawn & Garden Equipment. Recreational Transportation Equipment. Capabilities: Custom Casting CNC (Computer Numerical Control) Machining Finishing and Engineering Services Specializing in tight tolerances, pressure tight, quality finished parts in a wide range of types and sizes.

Quality Assurance Simulation Software blueprints production beforehand to ensure quality. Vacuum-assisted die-casting to improve structural integrity. Computer modelling to identify all adjustments necessary for your custom specifications.

Twin City Die Castings Inc.

Sales Volume: $20 - $30 Million End Markets: Aircraft, Aerospace, Automotive, Commercial Equipment & Products, Computers & Office Equipment, Consumer Products, Defence, Electronic Equipment, Hydraulic & Pneumatic Equipment, Industrial Equipment & Machinery, Lawn & Garden, Power Tools, Pumps & Compressors ,Transportation - Non-Automotive. Capabilities Twin City Die Castings maintains 240,000 sq. feet of space. The company has approximately 26 die cast machines ranging in size from 350 to 1000 tons. They also have a joint venture in India.

Quality Assurance The company has various devices for inspection and ensuring the highest quality and follow industry standard quality control methods.

Crecocast
Sales Volume: Under $10 Million

End Markets: Commercial Equipment & Products. Power & Hand Tools. Recreational Transportation Equipment.

Capabilities 36,000 Square Foot Building 100+ Acres, Rural Area, Landscaped. Geothermal cooling system through coils submersed in lake. Visual Enterprise Integrated Software-production, shipping, inventory control and manufacturing. Complete network of workstations. Complete system of modern storage racking and material handling equipment Zinc Die Finishing equipment include: 1. Tumbling Barrels ( Various Types) 2. Roto-Finish Vibratory Finisher 3. Washer & Dryers (custom built) 4. High Energy Disc Finisher 5. Rotary Separators

Quality Assurance The company has various devices for inspection and ensuring the highest quality and follow industry standard quality control methods.

Meridian Magnesium Die Casting

Sales by Volume: Under $10 Million End Markets: Automobiles, Military , Trucks , Aerospace and Consumer Products. Capabilities: 22 die cast machines over 2500 tons Over 450,000 ft of manufacturing space Over 40,000 net metric tons of product shipped annually Many secondary machining, coating, and assembly capabilities that add value to the companys client partnerships. 4 North American manufacturing sites 1 European manufacturing sites 1 Asian manufacturing site 3 international sales offices.

Quality Assurance The company has various devices for inspection and ensuring the highest quality and follow industry standard quality control methods.