making it one of the largest and most advanced non-ferrous foundries in North America. The primary focus of the expansion was to create a straight- line workflow by moving departments, along with adding additional floor space and capacity.
State of the Art Facility
Starting shortly after the sale, O’Fallon Casting began overhauling the entire facility. Manual shell building was replaced with advanced robotics and conveyor systems. Small gas fired melters were replaced with 2000lb electric melters. Manual shell removal with high pressure water was replaced with an automated system, including conveyors, an automatic drag unit to remove the waste shell and a water recycling system to reuse the spent water. Down draft tables, dust collection and enhanced lighting was added to a new pre-inspection area that was twice
the size of the previous one. Heat treat capacity was more than doubled with the addition of new solution anneal and age hardening ovens.
The non-
destructive testing area now includes two digital radiography systems, including an automated 100-micron system. For dimensional inspection, a 3 headed laser scanner supplements two coordinate measurement machines. All of this is tied together with the Castit Business System, developed as a paperless, all-encompassing ERP system specifically geared towards the foundry industry. The business system is accessed on computers all across the plant, which are complaint to the latest DOD cybersecurity protocols.
Services Offered O’Fallon Casting pours Aluminum and Copper based castings, specializing in complex castings used in the Aerospace and Defense markets.
The
function of the castings supplied by O’Fallon Casting include thin walled electronics housings, complex cored pump and hydraulic applications and tight tolerance optical housings. Casting services include rapid prototypes, low and high-volume production castings, solidification modeling, non-contact inspection and digital radiography. Castings, though, are only a part of what O’Fallon Casting has to offer. O’Fallon Casting also provides concurrent engineering, subcontract management and onsite training programs to its customers, helping them gain a better understanding of the Investment Casting process. With it’s newly completed
expansion, talented workforce, state of the art equipment and a culture geared towards customer service, O’Fallon Casting is ready to meet the growing needs of the Aerospace and Defense industry for many years to come.
August 2020 ❘ 23 ®
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