Production Technology

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At Mars Metal our team of experienced designers, engineers, and trades people find innovative ways to use advanced manufacturing technology to keep costs low while maintaining the highest in quality standards. We are continually developing new methods and materials for our pattern construction, custom molding design and production methods. Combined with the actual production is the use of destructive pre-production testing and non-destructive in-production testing for our products. Our casting technology is constantly evolving as we generate modifications to tooling designs and casting methods to produce very high quality castings in a safer and more sustainable manner.

In terms of our physical capacity Mars Metal is second to none. Our continuous lead casting capacity is in excess of 200,000 lbs. or 91,000 kgs. Our CNC machining and fabrication capacity is X-60’, Y-20’ and a maximum weight of 60,000 lbs. We also have the ability to cast ferrous and non-ferrous metals.

Patterns
Production and Custom Patterns and Plugs produced from prints or IGES Files Patterns for High Production runs and one-off customPatterns on Match Plates for Iron, Stainless Steel and Bronze Castings Pattern Construction up 50 ft. in length and 16 ft in height CNC Machined part tooling and fixtures available
Lead Alloy Casting
Casting up to 200,000 lbs.
Production and Custom one-off castings
Design Consultation for High Performance castings
CNC Machined finishes
Custom coating applications
Ferrous and Non-Ferrous Castings
Lloyds Register Certified Foundry
Ferrous
Up to 4500 lbs net cast weight
Heat-resistant stainless steels
Corrosion resistant stainless steels
Carbon, low-alloy and tool steel
Non-Ferrous
Up to 9000 lbs net cast weight
Beryllium copper
High-conductivity copper
Bronze
Aluminum
CNC Turning
8 Units, 3-Axis Capability cw Live Tooling
Maximum Swing: 38″
Between Centers: 165″
Bar Feeder: to 1.75″ Dia.
CNC Machining
For patterns up to approx. 10,000 lbs (cast weight) the router can cut the patterns directly. For patterns larger then that the router is used to cut the needed sections or stations and associated shapes to assist our existing pattern shop. This machine allows the cutting of large intricate shapes cut in single piece or as a group of interlocking shapes (puzzle parts) that make up a larger part.
CNC Horizontal Mills
5 Units, 5 axis.
Max. Spindle Dia: 6″ (152.4 mm)
Max. Travel: 110″ x 360″
Max. Table Size: 96″ x 320″
Equipped with gundrilling attachment.
Conventional Turning
4 Units
Max. Swing: 50″
Between centers: 360″
Fabrication Available
CWB Approved, to CSA Standard W47.1 in Division 3.
Custom Fabrications in Steel, Stainless Steel and Aluminum.
Welding processes, MIG, TIG and Stick
Plate Forming and straightening available
Plate Shear, 20′ long x 1.25″.
Bending Forming, 1000 ton x 24″, 800 ton x 31′
Plate Rolling, largest is 16′ x 22.5″