Aluminum Die Casting

Blue Ridge Pressure Castings manufactures highly complex aluminum castings to the highest standards for precision, quality and delivery of the world’s most demanding customers.  Our team of engineers and manufacturing professionals works with our clients to accomplish their goals.

  • Low Cost – After the initial tooling and development expenses, die casting becomes one of the most cost effective methods for producing high volume parts.
  • Design Freedom – Thin wall castings provide sheet-metal like finishes with much greater design flexibility.  The die casting process allows complex surface details and the incorporation of attachment bosses, tabs and structural features which cannot be achieved with either sheet metal stampings or injection molded plastics.
    • Part Integration – because die casting can produce highly complex shapes very precisely, many features such as bosses, cooling fins and cores can be incorporated into one piece thus reducing overall weight and cost while improving quality and strength.
    • Class-A Surfaces – Blue Ridge is one of the few die casters who have mastered the design and manufacture of parts with automotive class-A surfaces which can be chromed or painted.  Parts meet both functional and esthetic requirements
  • Weight reduction – Aluminum provides an optimal balance of strength, weight and cost making in excellent material for weight sensitive applications requiring durability and strength.
  • Dimensional accuracy and stability – Aluminum casting produces parts that are durable and dimensionally stable, while maintaining close tolerances.
  • High-speed production – Aluminum die casting provides complex shapes within closer tolerances than many other mass production processes. Little or no machining is required to produce thousands of identical castings.
  • Heat Dispersion – No other material has both the dimensional flexibility and heat dispersion characteristics of die cast aluminum.  Many applications requiring cooling utilize our processes.
  • Heat Tolerance – Die cast parts can match the complexity found in plastics while operating effectively in high heat environments.
  • Strength and weight – Pressure cast aluminum parts provide greater strength than plastic injection molding for the same dimensions.  Incorporating features rather than attaching them in separate operations reduces assembly time, increases quality and improves strength.
  • Multiple finishing techniques – We produce aluminum die cast parts with smooth or textured surfaces which can easily be plated, coated or finished with a minimum of surface preparation.
  • Simplified Assembly – Aluminum die castings provide integral fastening elements, such as bosses and studs. Precise corings simplify tapping.  Integration of threads in the mold design phase eliminates additional fasteners for assembly processes.  Integrated tabs and bosses and registration features further reduces part count and improves assembly quality.
  • Alloy Selection – Selecting the correct aluminum alloy for the application and designing the component to exploit the characteristics of the alloy and the die cast process allows OEMs to reap the full benefits of aluminum in many applications.  We provide the expertise to deliver.
  • Corrosion Resistance – In applications demanding a high tolerance to corrosive environments, aluminum offers distinct advantages over alternative materials.  When combined with the correct coating technology for the application – aluminum parts provide the best combined durability against salt, water and UV damage.

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