Driven by an unwavering commitment to delivering services/products of the highest standard, Fondmatic takes meticulous care throughout the production process, with thorough controls at every stage. The culture of quality is applied across every aspect of production, from goods inwards right up to when the final product leaves the foundry.
To best meet customer needs, the Engineering and Time and Methods departments make their experience available during all design stages. The team uses CAD, CREO1 and casting simulation software to optimise times and costs when creating tooling and castings. A rapid prototyping service has been developed to reduce sample delivery times and offer the opportunity to change the shape of a workpiece in progress, without affecting development costs.
The shop has automatic measuring tools for fine-tuning and monitoring the equipment, so that we can ensure patterns and core boxes meet stated requirements.
Suppliers, raw materials and core production processes are continuously monitored to ensure that the end product is of high quality. Automatic core blowing machines, and painting and finishing stations allow the most complex hot-box core production, which can assemble as many as more than 10 cores.
(flasks 600x740x250+250 – rate 150 moulds/h)
Automatic pouring and in-line furnaces and are equipped to produce castings with a unit weight ranging from 1 to 60 kg.
An annual capacity of 45,000 tonnes achieved with:
- 3 rotary casting furnaces
- 1 induction holding furnace
- 1 induction automatic castings furnace for Grey cast iron
- 1 induction automatic castings furnace for Ductile cast iron
|Casting||Grey Iron||Ductile Iron|
|Standard||UNI EN 1561||UNI EN 1563|
The finishing department offers sandblasting, fettling and finishing processes, and automated systems have been installed to provide an integrated cycle. The product is subjected to quality control at each stage through specific sampling plans, which in some cases are designed around how critical the individual casting is:
- Sandblasting: belt sandblasting machines
- Fettling: robotic islands as well as bench and portable grinders are used for fettling in a designated area on site;
- Finishing and inspection of hydraulic castings: automatic machinery and lines for internal sandblasting and endoscopic inspection stations ensure the highest quality hydraulic products.
FDM’s integrated process ensures that the required quality and efficiency results are achieved, in accordance with the international materials standards.
- Raw material acceptance checking includes radiometric checks and visual inspection on 100% of incoming materials, as well as sampled checks.
- The melting process, an essential stage of the company’s core business, is monitored from when the material is loaded up to the basic analyses.
- The liquid metal is then taken to the casting station, where its main characteristics are checked to ensure that they comply with the in-house standards applicable to the casting being produced.
- Material process control is performed by producing separate casting specimens to determine their mechanical properties and ensure that the process and product are compliant.
- Finally, the castings continue to the cooling station, where the cooling times are based on the average casting thickness to ensure that the microstructures are compliant.
To complete the integrated process, the product undergoes the following checks:
- Hardness, sampled visual inspection;
- Metrological checks on all codes for submission to the PPAP (Production Part Approval Process).