Why State Line Foundries

Several ounces up to 3,500 lbs.

We pour all ASTM standard grades of Gray Iron, Ductile Iron, Austempered Ductile Iron, and HiSilMoly. We also pour custom iron alloys per customer requirements.

Our niche is low to medium volume. We produce 1 piece orders, and orders exceeding 3,000 pieces. Our average order quantity is about 10 pieces. The annual demand we can keep up with will be part specific depending on size, complexity, and many other variables.

Yes, we do stress relief and annealing heat treatment processes in-house. Other heat treatment needs are outsourced to local, trusted suppliers.

Once the transfer pattern tool is received, our foundry engineering team evaluates its overall condition. We first review the drawing and the tooling to ensure we have everything: the pattern set, core boxes, loose pieces, etc.

Next, we determine the best setup for our foundry based on demand volume, casting complexity and customer requirements. Our sales team sends a quote to the customer for the cost to adapt the pattern tool.

If the customer approves, then our in-house pattern makers will do the work necessary to adapt the pattern tooling to be used in our foundry. We bring in over 250 transfer patterns per year.

YES! We excel at producing iron casting prototypes for our customers. We use tried and true methods, as well as the latest technologies, to provide prototype castings to our customers.

The first step is to have a dialogue with the customer to determine the needs of the project. From there, we can quote the best options to meet their requirements. Tooling options include 3D sand printing molds and cores (patternless castings), foam pattern tooling or short lead time hard pattern tooling. Then we expedite the casting processes. Lastly, we have in-house lab capabilities to promptly meet most PPAP/FAI requirements to certify the prototype castings.

We do not offer product design services specific to the customer’s product line, but we do offer design services to support producing their castings. Some examples include:

• Providing feedback to customers to improve the castability of a part.
• 3D scanning an existing casting to produce a model and drawing.
• Creating a casting model from an existing 2D drawing
• Designing pattern tooling for producing sand molds and castings.
• Create models used for 3D sand printing molds and cores

We utilize MAGMA for solidification modeling.

Yes, we have dedicated pattern makers in-house. Our pattern makers adapt transfer tooling, make state changes, perform maintenance on patterns and do some design modifications. We outsource new pattern builds to several local, trusted pattern makers.

We utilize trusted, local machining sources to provide our customers with machined, complete castings.

24 hours.

Books have been written to answer this question. A simple answer is utilizing our extensive foundry experience, the latest casting technologies such as MAGMA solidification modeling and rock-solid processes and procedures. Our niche is low-volume, high-mix, which results in gaining a lot of casting experience reviewing a wide variety of casting geometries, complexities and challenges.

Yes, we have the same or better lab equipment that can be found in any large foundry, including:

• A spectrometer for checking the chemistry of the casting.
• A microscope for checking the micro-structure of the iron
• A tensile machine for testing the physical properties of the iron
• Equipment for checking the Brinell hardness of castings
• Green sand testing equipment
• No-bake sand testing equipment

We routinely cut up castings in-house to check their internal soundness. We also utilize local sources for non-destructive testing such as radiographic inspection and magnetic particle inspection. Utilizing MAGMA solidification modeling on the front end helps greatly reduce the possibility of porosity being found during destructive and non-destructive testing.

98% of the time we make a casting for the first time, those castings are quality, approved castings. This is proof that our new job startup processes are effective. Also, this reduces overall lead times for prototype and sample castings, allowing production orders to begin sooner.

High-volume foundries may have a customer or a package of work that includes a need for lower-volume castings. They often delegate that work to us.

We also help by producing prototype castings and by filling early production orders while new foundry tooling is being developed for several high-volume foundries. They come to us because they trust us to deliver high-quality castings on time. We can produce them to their quality requirements, in low-lot orders.

Large foundry capabilities but in a low-volume niche.