Our services. All under one roof
Your project in expert hands
Before the first melt is poured into the mould, we discuss with you exactly what your component needs to be capable of in practice and what further steps are required to complete your product.
This is because MKB products generally leave our premises ready for installation. Where we are unable to carry out certain manufacturing
processes ourselves, we organise them through our partners, with whom we have been working for many years. We take full responsibility for managing the entire supply chain and remain your sole point of contact.
We also take care of the logistics for you and issue all the necessary documents for transport by the relevant mode of transport (road, sea, air).
This is how your metal casting project will proceed with us
Following the design of the mould, the next step is mould manufacture. Our highly capable specialist department takes the CAM data previously created during the design phase and plays a crucial role in ensuring the subsequent quality of the castings.
We use modern materials for our moulds to achieve optimum service life.
At the same time, fixtures for machining are prepared and finalised once the first test casting is available.
We find a solution. Our new design checklist shows you what is important when designing for casting:
- uniform wall thicknesses or controllable transitions in wall thickness, so that the component solidifies in a controlled manner.
- rounded edges instead of sharp transitions.
- draft angles on internal surfaces.
- Demouldability, verified against the finished geometry.
- No sharp edges.
- Reduce material build-up.
- Straighten cross-ribbing.
You can download the whole document as a PDF, complete with detailed information. If you prefer, we can also go through your design with you.
Tolerances and reference dimensions determine just how labour-intensive the machining will be later on.
During the structured product review, we then record the key technical specifications and immediately check whether they are suitable for casting. For us, it becomes economically viable from 25 pieces per batch.
We design the casting mould using computer-aided design, and our toolmaking department then manufactures the mould from the same data. This has a major advantage: should we need to make any changes following the trial casting, we do not have to wait for an external toolmaker. In parallel with this step, the jigs for machining are already being developed, which we manufacture after the first trial casting. Where necessary, the mould is supplemented with steel inserts and/or sand cores, so that undercuts and cavities can also be produced.
Casting is carried out in accordance with EN 1982 for copper-based alloys and EN 1706 for aluminium. We manufacture the rough castings in accordance with DIN EN ISO 8062-3. Each batch is tested for its chemical
composition, and the results are documented. This is particularly important if you need to provide material certificates for the railway or electrical industries.
Before the first clamping operation takes place in the metrology department, we define the measurement strategy together with you. We also take care of the assembly. We procure and stock purchased parts ourselves, as well as carrying out functional tests, so that complete sets are delivered to you.
Our partners take care of the surface finishes:
• Silver plating, nickel plating, chrome platin
• Anodising
• Painting
• Pressure impregnation
That leaves the logistics. And we’re happy to organise these in line with your packaging concept. Just let us know the maximum weight per packaging unit, and we’ll work within the guidelines of the Load Handling Regulations to find a solution that makes life easier for your staff in the goods-in department.
Because decision-making processes are streamlined here, we can sometimes prioritise urgent enquiries.
FAQ on metal casting and die casting
The component leaves our premises in the condition in which you will install it: machined where necessary, assembled if required and/or with a finished surface, and in your chosen packaging. With permanent mould casting, the casting skin is of such high quality [A1.1] that mechanical reworking is not even required in many applications.
We manufacture batches of 25 units or more. This process really comes into its own for small and medium-sized production runs, as the tooling costs are significantly lower than those for die-casting. However, larger quantities can also be produced just as cost-effectively.
Copper-based materials: non-ferrous metals, namely pure copper and copper-chromium alloys, copper-aluminium alloys, brass and aluminium alloys. For our customers in the electrical and railway engineering sectors, as well as in medical applications, we primarily cast copper and copper alloys in accordance with EN 1982, as well as AlSi and AlZn alloys in accordance with EN 1706. On request, we can also supply MKB special alloys.
By email as a STEP file, JPG or PDF; drawings are also acceptable. We will then get in touch with you personally within a few days to discuss the next steps.