At Bremer Manufacturing Company, Inc., we’re your go-to source for all custom complex aluminum sand castings. We are experts in our field, here to help you get the job done faster, more efficiently and with better quality than ever before.
We are a trusted aluminum foundry for sand casting aluminum, including both automatic green sand molding and air set casting. We have also expanded into additional secondary operations, including core making, CNC machining, grinding, burnishing, heat treating and more. We’re a trusted partner for our clients across numerous industries, including heavy trucking, agriculture, automotive, industrial lighting and more. Our commitment to quality and customer satisfaction has allowed us to build long-lasting relationships with our clients, who trust us to consistently provide them with top-notch products and services.
We specialize in custom aluminum sand casting because unlike permanent mold and die casting, it’s the most versatile method available for custom aluminum sand casting parts and products. We’ve offered this method for over 75 years with operations that include core making (utilizing industry-leading Redford machines), green sand casting (utilizing Hunter Automatic Molding Machines) as well as air set molding — also known as no-bake molding. If you’re ready to discuss your project or request a quote, give us a call or contact us today. We’re here to turn your ideas into high-quality custom aluminum castings.
Benefits of Quality Aluminum Sand Casting
Sand casting aluminum allows for several direct benefits across various applications:
- Design versatility: Aluminum sand casting helps create intricate designs and complex shapes, allowing for more design flexibility. This is especially useful for creating custom parts and components.
- Cost-effective: Compared to other production methods such as CNC machining or forging, sand casting aluminum is generally a more cost-effective option. This is because the tooling and equipment required for sand casting are generally less expensive.
- High strength-to-weight ratio: Aluminum sand castings have a high strength-to-weight ratio, making them ideal for applications that require lightweight yet strong components. This makes them popular in industries such as aerospace and automotive.
- Corrosion resistance: Another benefit of using aluminum sand casting is its natural corrosion resistance. This makes it suitable for use in outdoor or marine environments without the need for additional coatings or treatments.
- Thermal conductivity: Aluminum has excellent thermal conductivity, making it a popular choice for heat transfer and dissipation applications. Sand casting allows for precise control over the thickness and shape of the component, further enhancing its thermal properties.
- Recyclability: One of the most significant benefits of using aluminum in any manufacturing process is its recyclability. Aluminum is infinitely recyclable without losing any of its properties, making it a highly sustainable material choice for sand casting.
Custom Aluminum Sand Casting Process & Equipment
Ranging from the most basic parts that weigh just a few ounces to extremely complex shapes weighing up to 120 pounds, our tried-and-true custom aluminum sand casting process (which includes warmbox and shell core production) will accommodate practically any need. These processes and state-of-the-art equipment include:
- Three Redford-43 machines
- Three Redford-22 machines
- A fleet of Hunter Molding Machines:
- One Hunter HPM Automatic molding machine (14”X 19”) Flask
- Three Hunter HPM Automatic molding machines (20”X24”) Flask
- 12 Electric aluminum melting crucibles that produce aluminum sand castings from ounces up to 30 pounds
- An air set molding line that includes:
- High speed sand/binder mixer, 3 electric aluminum melting crucibles, automatic mold shakeout and sand reclamation system. Produces custom aluminum castings ranging from five pounds to 120 pounds, in flask sizes up to 48” x 60”
- Alloys poured include 319, 256, A356, 357, 359, and 535, per Aluminum Association Standards. Heat treatments, performed in-house, include T5, T51, T6, T61 and T7
- A quality control system that includes the analysis of various elements to verify chemical composition (and quality) of incoming ingots from suppliers
- In addition to being a custom sand casting manufacturer, Bremer has in-house machining capabilities, utilizing eight Haas CNC vertical machining centers. Assembly operations include inserting thread inserts, dowels, pressing in tubes, studs, plugs and other components.
Industries We Serve
Through our quality sand casting aluminum services, plus our various secondary services such as CNC machining, heat treating and other secondary operations, our team at Bremer is able to serve several major industries:
- Automotive: Our precision aluminum castings and machined components are used in various automotive applications such as engine blocks, transmission housings, steering knuckles and more. From auto racing to general automotive production and repair, our parts are found in vehicles all around the world.
- Aluminum diesel engine castings: We are a trusted supplier of aluminum diesel engine castings for marine and industrial applications. Our team has the expertise to produce complex, high-quality castings that meet the specific requirements of each project.
- Food industry: Our aluminum sand castings are also used in the food industry for equipment such as mixers, grinders, and conveyor systems. Our castings are FDA approved and meet the strict standards for hygiene and safety.
- Lighting: The lighting industry also relies on our aluminum sand castings for a variety of applications. From streetlights to stadium lighting, our castings provide the strength and durability needed to withstand harsh weather conditions while maintaining their structural integrity.
- Electrical: The electrical industry requires high-quality components to ensure safe and efficient operation. Our aluminum sand castings are used in the production of electrical enclosures, connectors, and other critical parts. They offer excellent conductivity and thermal properties, making them ideal for electrical applications.
- Small engine: Our aluminum sand castings are also used in the small engine industry, particularly for manufacturing engine blocks and other key components. With their lightweight yet strong nature, our castings help improve the overall performance and fuel efficiency of small engines.
Commitment to Quality
When you work with our team at Bremer for all your sand casting aluminum and related complex sand casting needs, you can trust in our commitment to quality. We understand that your products and applications require precision and durability, which is why we have strict quality control measures in place throughout the casting process.
From the initial design phase to the final inspection of finished castings, we ensure that every step meets our high standards for quality. Our experienced team uses state-of-the-art equipment and techniques to produce top-notch sand castings that meet or exceed industry standards.
In addition, we continuously invest in research and development to improve our processes and offer innovative solutions for our clients. This dedication to continuous improvement allows us to stay at the forefront of sand casting technology and deliver exceptional results for our customers.
Contact Us
So if you’re looking for sand casting aluminum solutions or various related services surrounding CNC machining parts, Bremer Manufacturing Company, Inc. is the perfect partner for you. Our team of experts has years of experience and knowledge in the industry, ensuring that your project is in good hands from start to finish. We are dedicated to providing excellent customer service and exceeding expectations with our high-quality products, no matter your specific needs.
