Production Methods
Our partners are specialists in metal casting processes who work with all common raw materials.
Thanks to our broad portfolio of manufacturing processes, we have the right contacts to carry out the subsequent mechanical processing, surface treatment, and assembly of your castings.
We will find the right casting process for your requirements based on the complexity and quantity of your products. Our partners ensure adherence to high quality standards at a European level. A selection of our most common processes includes aluminum, zinc, and magnesium pressure die casting, as well as precision casting and continuous casting.
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Core Competence Pressure Die Casting: Cost-Effective and Flexible
Pressure die casting is one of astria's core competences. It is a flexible manufacturing process for different alloys, including zinc, aluminum, and magnesium. Aside from increased flexibility, you can optimize your costs right from the start, as we also use our affordable tools for small and mid-volume production runs.
Production
We produce different sized runs with batch sizes of between 500 and 100,000 units. Our machinery includes plant with closing forces from 200 to 7500 kN. Depending on the complexity of the parts to be produced, we use open/close and slide tools with one and two-dimensional alignment. We also carry out mechanical finishing, surface coating, and pre-assembly on request. Furthermore, all our production processes are ISO 9001-certified.
Alloys
Different applications require different mechanical properties. We use the three most common pressure die casting materials: zinc, aluminum, and magnesium. Each of these is then broken down into further sub-alloys in order to meet the specific customer requirements. The benefits speak for themselves: high corrosion resistance, strength and hardness, high electrical and thermal conductivity, as well as optimal processing properties.
Services and Lead Times
Our pressure die casting services include component engineering, DFM (Design for Manufacturing) analysis, Moldflow simulation, tool design, mold construction, tool construction, and parts manufacturing. Surface treatment is carried out according to customer requirements. The most common processes are glass bead or sand blasting, wet lacquering, powder coating, and anodizing.
For tool construction and the first sample parts, lead times are 6-8 weeks. Parts can be manufactured within a few weeks.
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Best Practice: Sunshade Manufacturer
The joint of the awning is manufactured by astria using pressure die casting. Thanks to our cost-effective tools, this production method is the perfect choice for a batch size of 1000 units. Pressure die casting allows joints and the covers to be manufactured that are resistant, durable, and of a high quality. The surface is glass bead blasted after mechanical processing. All parts are manufactured to ISO 9001 standards.
At the beginning of a project, customers often contact us with an initial design drawing or concept. We then draw up a DFM (Design for Manufacturing) analysis and agree on the most important parameters such as interface lines, injection points, visible areas, and surfaces. In addition, we jointly define the quality criteria according to which the parts will be assessed for acceptance at the end of the process – after all, high quality and satisfied customers are the top priority for astria.
In the Moldflow analysis, we simulate all phases of the pressure die casting process from material injection to holding pressure. Here the material flow, temperature curves, and cooling are simulated in order to analyze shrinkage, warpage, sink marks, weld lines, and air inclusions in advance. This forms the basis for the necessary corrective measures to be adopted in the design or process. As a result, we are able to prevent tension and surface errors, and to meet the dimensional and aesthetic requirements of the customer from the very beginning.
"Together with astria, we have already implemented numerous pressure die-cast components and have always been satisfied with the results. We value reliable partners like astria, who place great emphasis on product quality and adherence to delivery dates."
Purchasing Manager, Graz-based sunshade manufacturer
Experience and expertise
in many industries