The Perla AluCast process in 10 steps
At Perla AluCast, we work with a fixed step-by-step plan when going through the total casting process. For each one of these steps, you can join us as a new customer or ask us for advice. Do you have an initial sketch or product idea? If you wish, our experts can take over the design procedure for you, while an initial 0 series can be produced for customers with an existing and properly functioning mould. And between these two alternatives, there are many possible options. Feel free to ask us about the possible options, free of obligation.
1. Determining the design criteria
As far as the function of your aluminium casting is concerned, it is very important to clearly define the product requirements. The degree of water-tightness can be important and therefore the IP class, the degree of corrosion resistance or the protection against EMC influences, for example. By taking these values into account during the initial stage, you will save significant costs at the end of the casting process. During this step, you will record the total package of requirements together with our experts.
2. Co-engineering your product
If you have a product idea or a sketch of a new product to be manufactured, we would be happy to help you develop the ultimate casting product from an early stage. This way, you are assured that the product can actually be manufactured for the lowest possible costs using the right casting method in the highest repeatable quality. We can take this design work off your hands.
3. Completing the design procedure
In this phase, the 3D models are completed and optimised for the chosen casting process. The product is assessed in combination with other components in the CAD system. Tests can also be carried out, such as a strength test using FEM analysis. A prototype can be made (for example, using 3D printing) to rule out any uncertainties. The 2D drawings are also created during this process and the desired (and attainable!) tolerances are recorded.
4. Design freeze for the technical drawings
When the design procedure has been completed and you and our experts are completely satisfied, this design is recorded and “frozen”. From this point, the design component is officially completed and work can start on the next steps.
5. Tool design / designing casting tools
We design the mould according to the final design of your product. Thanks to the extensive experience of our experts in this area, we know exactly how to identify possible sticking points when the mould is ultimately being produced and when it is being used in the foundry. By paying extra attention to these points during this phase, any uncertainties will be ruled out for the remainder of the procedure. During this step, we use special software to test the functionality of the mould.
6. Production of the mould
As soon as our experts release the mould design, we manufacture the mould in our own tool shop. The normal turnaround time for this task is approximately 6-8 weeks, depending on the size and complexity of your product. Because we perform this important and expensive task ourselves, you can be assured that your mould will be produced within the agreed period and for the agreed price. And even more important: that the mould meets all of the requirements. After all, this is the mould we ourselves will use for casting!
7. Trial casting
Now that the mould has been produced, we use it to perform the first trial casting of your product. We then send the FOT (First Out of Tool) samples to you for your approval, including a measurement report and (if you wish) a material certificate.
8. 0 series
Once you have approved the samples (or after any adjustments of the mould and a new trial casting), the mould is definitively hardened. We use the hardened mould to produce a 0 series. You can use this series to perform physical tests and configure your further (assembly) processes. We use the products from the 0 series to optimise any finishing moulds, measurement gauges, etc.
9. Series production
After the first delivery has been agreed with you, the planning schedule is communicated and Perla AluCast can run the first complete serial production.
Because we discussed a large number of the previous steps together with you, in almost all cases we deliver this first series of assembled (end) products with zero defects and no errors.
You can also rely on our support once the products are ready. Needless to say, we provide the transport from our factories in China or India and import the product to our warehouse in the Netherlands. Do you want your product to be delivered elsewhere, in special units or every week on the same day? No problem. We can also reserve stock for you in the Netherlands, so that you are always assured that your product will be delivered on time. Our specialists will be happy to discuss the possible options with you.