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Automation-led aluminium die casting, engineered for volume.

Four stages, one accountable team: melt, cast, heat-treat and inspect, all on the same floor.

SectionProcess

Melt → Cast → Heat treat → Inspect.

Tower-type melting
01 · Melt
Tower-type melting

Six tower furnaces, verified chemistry every melt.

A continuous melt of AC2A, LM16 or Al-Si7 is held to spec and verified by optical-emission spectrometer before any metal enters a die. Holding-bath temperature is PLC-controlled and logged against the part-specific recipe.

  • Furnaces6 × tower
  • AlloysAC2A · LM16 · Al-Si7
  • Pour temp680 – 740 °C
  • Chemistry QCOE spectrometer
Gravity die casting
02 · Cast
Gravity die casting

44 GDC machines with auto-pour and PLC cycle control.

Cycle time, pour profile and die-temperature traces are logged for every shot, giving us the process-capability data Tier-1 customers need at PPAP and through volume production. Part-weight range 100 g to 1.5 kg.

  • Machines44
  • Auto-pourStandard
  • Part range100 g – 1.5 kg
  • TraceabilityPLC-logged
In-house heat treatment
03 · Heat treat
In-house heat treatment

Solutionizing and ageing to customer-specified tempers.

T6 and customer-defined heat-treat cycles run under logged time-and-temperature traces against the control plan. Mechanical-property validation is performed in-house every heat-treat batch via tensile testing.

  • TempersT6 + custom
  • ValidationTensile / batch
  • LoggingTime–temp trace
  • AuditPer control plan
MetChem laboratory
04 · Inspect
MetChem laboratory

Chemistry, mechanical and dimensional verification, in-house.

Our in-house MetChem laboratory provides spectrometer chemistry analysis, tensile testing and dimensional / metallurgical inspection on the same floor as the casting line. Reports are issued against a robust control plan and made available to customers on request.

  • ChemistryOE spectrometer
  • MechanicalTensile tester
  • DimensionalCMM (planned)
  • SystemIATF 16949
SectionAlloys

Alloys, chosen for braking duty.

Each alloy is matched to a component's role in the brake system: structural caliper bodies, bore-tolerant cylinders, or weight-optimised brackets. All three are cast in the same plant under the same QMS.

Swipe to compare →

PropertyAC2AHigh strength · structuralLM16Heat-treatable · balanced
Primary UseCaliper bodiesMaster cylinders · bracketsMaster CylinderBrackets
Silicon (Si)~5%High-strength matrix~5%Balanced casting
Copper (Cu)~4%Strength contribution~1.5%Moderate
Iron (Fe)< 0.3%Improved Ductility< 0.6%Moderate
Heat treatmentT6 standardSolution + ageT6 standardSolution + age
Strength characterHigh UTSStructural-gradeBalanced UTS / ductilityWorkhorse
Typical platforms2W · 3W · 4W*Safety-critical2W · 3Wvalue engineered

* Four-wheeler caliper programmes in development. Specific chemistry, mechanical properties and acceptance criteria are issued per part on the customer's drawing & control plan.

SectionEngineering

More than a casting house.

We work with customer engineering from the first sketch, feeding back manufacturability, value-engineering opportunities and tooling realities before a die is cut.

DFM

Design for Manufacturability

We review every new geometry against gravity-die-casting realities (wall sections, draft, gating, hotspots) and feed changes back during RFQ, before a die is ordered.

Output:annotated DFM report · proposed revisions
VAVE

Value Analysis / Value Engineering

On running programmes we propose weight, cycle-time and material-cost reductions. The VAVE tandem master cylinder is our anchor case: a multi-feature casting, fully re-engineered.

Output:VAVE proposal · sample · validation plan
TOOL

Tooling via Renuka Engineers

Tools are designed, built and reworked at our sister facility, Renuka Engineers, keeping die ownership and turnaround inside one accountable group.

Output:tool drawings · die · rework cycle
PPAP

Sampling & PPAP

From first-off samples through dimensional layout, capability studies and PPAP submission: the documentation set Tier-1 buyers require before SOP.

Output:PPAP file · CpK data · IMDS
SectionDesign & development

You own the design. We engineer how it's made.

Every programme begins and ends with the customer. You bring the part; we bring its manufacture. Through this loop we take your drawing to validated, sampled castings — while design authority for the product stays with you at every step.

01

Design for Manufacturability (DFM)

Review casting design against our gravity die-cast process constraints.

02

Design Simulation

Thermal and flow simulation to optimize gate, riser, and cooling.

03

Tooling Design & Build

Die design and CNC machining in-house via Renuka Engineers.

04

VAVE & PPAP

Value Engineering, Process approval documentation per IATF 16949.

05

Prototype Trials

First-article production runs and metallurgical validation.

06

Production Readiness

Control plan finalization, SPC setup, full-rate production.

Manufacturing process and tooling design sit with MAP Alloys; product-design authority remains with the customer — consistent with the scope of our IATF 16949:2016 certification.

SectionHow we work

From RFQ to SOP: the way OEM sourcing actually works.

A typical new programme moves through these seven stages. Lead times below are indicative; firm timelines are quoted against component complexity and tooling scope.

01

RFQ

Wk 0 – 1

Drawing intake, NDA, alloy & volume review.

02

DFM review

Wk 1 – 2

Manufacturability feedback, geometry & gating proposal.

03

Tooling

Wk 2 – 12

Die design & build at Renuka Engineers.

04

Sampling

Wk 12 – 14

First-off castings · dimensional layout · chemistry & mechanicals.

05

PPAP

Wk 14 – 18

PPAP package · CpK · IMDS · run-at-rate trial.

06

SOP

Wk 18 +

Start of production, capacity ring-fenced to schedule.

07

Volume & VAVE

Ongoing

Continuous improvement, VAVE proposals, scope expansion.

Ready to start a programme?

Request a Quote→See the plant