M-Wave’s metal parts fabrication offerings are geared to industrial and commercial original equipment and contract manufacturers that require custom, labor-intensive parts that are specified with a wide range of alloys, finishes and processes – primarily aluminum and steel.
In metal parts fabrication, content ranges from merchant grade steel to high alloy aluminum and sheet metal enclosures as a several examples. The common denominators are: the metal products are custom, they require higher amounts of labor in finishing, there are low-volumes but generally higher mixes, and potentially higher unit values of the finished products.
Aluminum is the established metal of choice for the production of light weight components in the automotive, aerospace, transportation and commercial controls industries.
M-Wave metal parts fabrication may also be for tool and die-making when high domestic costs dictate Asia options. We can take your build-to print-specifications and obtain the best sourcing and the lowest price on a case-by-case basis. This is usually the case where ultimate tooling may result in low-volume, high-mix metal parts fabrication as well.
CASTINGS – There several types of casting processes that MWI partners utilize include:
Die Casting (Aluminum parts or components)
Casting liquid aluminum alloys into metal molds using processes such as gravity, low pressure and high pressure die casting is a cost effective means of producing complex shapes that require minimal machining.
Die casting is the method used for forcing molten metal into mold cavities under high pressure. Die casting is very versatile and hence, is the widest used method for casting a metal. Die casting is same as permanent mold casting the only difference is that the metal is injected into the mould at very high pressure of 10-210 Mpa (a measure of pressure to stiffness). This results in a more uniform part, usually good dimensional accuracy and also good surface finish. M-Wave limits itself to projects that require aluminum and various alloys.
Sand Casting (Aluminum components)
Casters use sand mixed with a bonding agent to create a mold around the item to be cast. The item, or pattern, is removed very carefully revealing the mold. If there will be any empty spaces in the finished product then a core is added to the mold. The core can be made of sand and is placed so that the molten metal fills the area of the mold around it. MWI can cast parts for clients based upon a requirement for sand casting at the best available LCC price.
EXTRUSIONS – Extrusion is the process in which long straight metal parts can be produced. The cross-sections that can be produced vary from solid round, rectangular, to L shapes, and T shapes. Also produced are tubes and other varying shapes. Extrusion is done by squeezing metal in a closed cavity through a tool, usually as a die using either a mechanical or hydraulic press. While a wide range of metal types utilize extrusion processes, MWI’s Asian partners focus on aluminum and other alloy parts and products generally associated with sub or final assembly work.
This process is done at room or slightly elevated temperatures. This process can be used for most materials subject to designing robust enough tooling that can withstand the stresses created by extrusion. Examples of parts that are cold extruded are collapsible tubes, aluminum cans, cylinders, gear blanks among many.
This process is done at fairly high temperatures, approximately 50 to 75 % of the melting point of the metal. The pressures can range from 35-700 MPa (5076 – 101,525 psi). Due to the high temperatures and pressures and its detrimental effect on the die life, good lubrication is necessary. Examples of parts produced by extrusions are: trim parts used in automotive and construction applications, window frame members, railings, electronics enclosures and aircraft structural parts, to name several.
CNC TURNING AND MACHINING
Turning is the process whereby a single point cutting tool is parallel to the surface. It is automated by using a computer controlled and automated lathe (or boring, knurling, and drilling processes) that increase the efficiency and limit waste. These types of machining tools are referred to as having computer numerical control, simply known as CNC machines. MWI process partners in Asia can handle a wide range of requirements for varying needs such as precision parts for the transportation, electronics, electrical, electro-mechanical and heavy machinery industries, as-well finishing processes for products associated with enclosures, racks and channels.
Sheet Metal Working (electronic box builds and enclosures)
M-Wave Asian partners manufacture a diverse range of custom enclosures including electrical and electronic box builds (sometimes called acoustical enclosures). MWI manufactures electronic enclosures for a variety of applications that may include: power generation, petrochemical, construction, energy, industrial controls, electronics, transportation, electro-mechanical and other commercial/industrial markets. Custom precision metal fabrication includes design and manufacture of electrical enclosures in stainless steel, mild steel, aluminum and galvanized metals; in almost any shape or size.
Asian capabilities include:
Other metal-working processes (ask for more details)
Whatever the requirement, M-Wave stands ready to work with OEM’s with low-volume, high-mix requirements in standalone products or as a part of a market-basket of electro-mechanical or electronic low cost country sourcing needs.