Simalex Manufacturing Company Ltd

In these images, you can observe the "hut" positioned over the crucible pot. Its purpose is to contain the SF6 gas (sulfur hexafluoride) used in magnesium die casting as a cover gas. This gas is pumped over the molten magnesium's surface to create a protective atmosphere, preventing it from reacting with oxygen in the air. To facilitate manual handling of the material to the shot cylinder, we must first remove the automatic ladling device. The "hut" has a trap door that is pneumatically activated by a foot pedal for this purpose.

While there are more automated and efficient methods for casting magnesium, Simalex's involvement in magnesium casting is limited. This is primarily due to the stringent safety requirements and the extended setup and teardown times associated with the process. Magnesium casting is provided more as a customer service to a select few clients who specifically request it. As such, we only undertake magnesium casting projects a few times per year.

CAD (Computer-Aided Design) is the use of computer software to create digital models of objects, while CAM (Computer-Aided Manufacturing) involves using software to control and automate manufacturing processes. In the machining industry, CAD is used for designing parts, and CAM translates those designs into instructions for CNC machines. The integration of CAD and CAM, often referred to as CAD/CAM, streamlines the transition from design to manufacturing, ensuring accuracy, reducing manual programming time, and enabling the machining of complex geometries. This integrated approach enhances efficiency and visualization throughout the entire production process.

Quality tags in a die cast manufacturing plant serve essential purposes such as identifying inspected parts, providing traceability through inspection records, documenting quality control measures, communicating critical information, monitoring work-in-progress, aiding in defect identification, contributing to process improvement initiatives, ensuring compliance with customer specifications and industry standards, and facilitating audits. These tags play a key role in maintaining and enhancing overall product quality throughout the manufacturing process.

Eye bolts are fasteners with a threaded shank and an eye or loop at one end. The threaded section allows secure fastening, while the eye serves as an attachment point for hooks, ropes, or other hardware. They are commonly used for lifting, securing loads, and as attachment points in various applications. Eye bolts come in different designs and materials, and they find use in lifting and rigging, load securing, suspension, and marine/outdoor applications. Safety guidelines should be followed to ensure proper usage and regular inspections for signs of wear or damage.

Die casting with magnesium is chosen for various applications due to several key advantages. Magnesium offers a combination of low density and high strength, providing a favorable strength-to-weight ratio. Its good machinability allows for the production of intricate parts, while its excellent thermal conductivity is beneficial for heat dissipation. Magnesium is also known for its electromagnetic shielding properties, recyclability, corrosion resistance, and vibration damping characteristics. Despite these advantages, material selection depends on specific application requirements, including cost, manufacturing processes, environmental considerations, and mechanical properties needed for the part.

A Brokk machine is a type of remote-controlled demolition robot used for various construction and demolition tasks. It is a compact and versatile machine that can access confined spaces and perform tasks that may be difficult or dangerous for humans to undertake. The Brokk machine is equipped with hydraulic attachments, such as hammers, breakers, crushers, cutters, or grapples, allowing it to carry out tasks such as breaking concrete, removing debris, cutting steel, or excavating. It is commonly used in industries like construction, mining, and demolition for its efficiency, precision, and ability to operate in hazardous environments.

Die cast molten aluminum is a captivating substance that combines fluidity and intensity. It is a molten alloy of aluminum and other metals, melted at high temperatures and poured into molds to solidify into desired shapes. The molten aluminum appears vibrant and radiant, with a shimmering silver-red hue. It flows with energy, resembling a fiery stream of molten metal, creating a captivating glow on its surface. Its fluidity allows it to fill intricate details in the molds, capturing precise textures and complex geometries. As it cools, the molten aluminum transforms into a solid object, reflecting the mold's shape and design. It becomes smooth and polished, showcasing craftsmanship and innovation. Die cast molten aluminum represents the merging of artistry and engineering, illustrating the creativity and skill in the casting process. It symbolizes the versatility of aluminum, which can be molded into various structures and decorations. The creation of die cast molten aluminum is a testament to human ingenuity in transforming raw materials into functional and aesthetically pleasing objects

Creating a workplace where friendships and laughter are encouraged is crucial for several reasons. It improves employee morale, happiness, and overall satisfaction, leading to increased productivity and lower turnover. Friendships enhance team collaboration, fostering camaraderie and trust among members. Laughter reduces stress by releasing endorphins, promoting relaxation and well-being. A positive and relaxed atmosphere stimulates creativity, innovation, and problem-solving abilities. Friendships also promote open communication, constructive feedback, and conflict resolution. Lastly, workplace friendships foster loyalty and commitment, resulting in higher retention rates and a more engaged workforce.

Die cast manufacturers may opt for manual grinding over CNC or robotic methods due to factors like complex part shapes, finishing control, and quality checks. Manual grinding allows for precise handling of intricate shapes and surface finishes, vital in some applications. It offers flexibility for custom or small-batch production and is often cost-effective. Skilled operators can visually inspect and address defects during manual grinding, enhancing quality control. For certain tasks like deburring and chamfering, human dexterity and judgment excel. While CNC and robotic automation are valuable, a combination of manual and automated processes is common to balance efficiency, cost, and precision in die-casting operations.

A "dock check" in QC inspection is a process where received shipments are visually inspected at a shipping or receiving dock. It involves reviewing documentation, counting items, and examining product quality. The goal is to ensure that received goods match the quantity and quality specified in purchase orders. Discrepancies or damage are documented, and decisions are made to accept or reject the shipment. This process helps maintain quality standards, prevent incorrect or damaged products from entering the supply chain, and facilitates communication with suppliers.

The "lost art" of manual machining refers to the diminishing practice of using hand-operated tools, such as lathes and milling machines, to shape metal and other materials. This decline is primarily due to the prevalence of Computer Numerical Control (CNC) machines, which offer automation, precision, and efficiency. CNC technology reduced the demand for manual machinists, leading to skill shortages and labor cost considerations. While manual machining remains relevant for custom work, prototyping, and unique tasks, it's increasingly rare in mass production. Despite its decline, manual machining is a valued skill and a testament to craftsmanship, often upheld by those who appreciate its traditional and hands-on nature.

Clear anodizing for die-cast parts serves to enhance their durability, aesthetics, and functionality. By creating a protective oxide layer, it bolsters corrosion resistance, increases surface hardness, and provides an attractive, reflective finish. Anodized surfaces offer electrical insulation and dielectric properties, making them suitable for electrical applications. They also improve adhesion, temperature resistance, and reduce friction. Additionally, clear anodizing can serve as a base for coloring or dyeing processes, offering versatility in design. In summary, clear anodizing is a crucial surface treatment for die-cast parts, ensuring they perform well, resist environmental factors, and maintain an appealing appearance across various industries.

Meet the Captain!

CEO. Plant Engineer | 30 Years
Fred is the third generation of Lyhnes to head up Simalex and loves knowing the company is still family-owned after all these years. He manages all aspects of Simalex’s operations, and also works on our tool engineering, robotics integration, quotes and inside sales support. Fred is a Red Seal journeyman tool and die maker and machinist. He is also an expert die casting engineer. He has over 30 years of experience in the die casting industry with Simalex and is qualified in SolidWorks, Inventor, AutoCAD, MasterCam, GibbsCam, CamWorks and Pro Engineer. Fred loves getting involved in sports, such as bodybuilding, powerlifting, football and hockey. He also loves drag racing and muscle cars.

A manual lathe is a mechanical device used to shape metal workpieces. Operated by skilled machinists, it rotates a workpiece against a manually controlled cutting tool to remove material and create desired shapes. Components include a bed, headstock with a spindle, tailstock for support, carriage with cutting tool, and tool post. It's versatile for turning, threading, and more. While CNC lathes automate processes, manual lathes remain valuable in workshops where experienced operators control precision machining. This piece of equipment can be particularly dangerous for an untrained person and must be treated with the utmost respect.

Apprentices are vital in manufacturing trades because they:
1. Develop practical skills and expertise.
2. Facilitate knowledge transfer and preserve best practices.
3. Bridge the skills gap and adapt to technological advancements.
4. Boost productivity and reduce turnover.
5. Foster innovation and offer career opportunities.
6. Support economic growth and competitiveness.

Benefits of Using an Adapter System for Die Casting Dies:

Versatility: An adapter system allows for greater flexibility and adaptability in die casting operations. It enables the use of different dies with varying specifications on the same machine or press. This versatility is particularly useful when dealing with different casting requirements, part sizes, or design changes.

Cost Savings: Adapters can help reduce costs by eliminating the need to purchase new or dedicated die casting machines for each specific die. Instead, the adapter system enables the use of existing machinery for multiple applications, maximizing equipment utilization and minimizing capital expenditure.

Reduced Downtime: Switching between different dies typically involves downtime for retooling and setup. With an adapter system, the changeover process can be quicker and more efficient. The ability to quickly swap dies using adapters can help minimize production interruptions and improve overall equipment productivity.

Continued in comments

In the context of CNC (Computer Numerical Control) milling, the term "4th axis capability" refers to the ability of a vertical CNC mill to rotate the workpiece around a fourth axis, usually referred to as the A-axis. A standard vertical CNC mill typically has three axes of motion: X (horizontal movement), Y (vertical movement), and Z (spindle movement). The addition of a fourth axis provides rotational movement to the workpiece.

The A-axis can be used to rotate the workpiece in incremental steps, allowing for complex machining operations and the ability to create features and contours that would otherwise be difficult or impossible to achieve with only three axes. With 4th axis capability, the CNC mill can perform continuous machining operations on the workpiece while rotating it, enabling the production of more intricate and detailed parts.

The A-axis is commonly used for tasks such as indexing, engraving cylindrical surfaces, cutting gears, creating spiral patterns, and machining complex profiles. It expands the milling machine's versatility and allows for the production of more complex parts with increased efficiency and accuracy.

Here are some considerations to help determine the right alloy:

Material Properties: Review the material properties of both alloys. ZA #3 is a zinc-aluminum alloy that offers good strength, excellent castability, and dimensional stability. AL383, on the other hand, is an aluminum alloy that provides high strength and excellent corrosion resistance. Consider the specific requirements of your die cast part, such as desired strength, hardness, ductility, and corrosion resistance, and choose the alloy that best matches those requirements.

Application and Functionality: Understand the application and functionality of the die cast part. Different alloys may have varying performance characteristics under specific conditions. Consider factors such as temperature exposure, load-bearing requirements, wear resistance, and any other relevant environmental or operational conditions. Choose the alloy that can withstand the intended application conditions and provide the necessary performance.

Design Complexity and Wall Thickness: Evaluate the design complexity and wall thickness of the die cast part. ZA #3 is known for its excellent fluidity, allowing it to fill intricate molds and thin walls effectively. If your part has complex geometries, thin sections, or fine details, ZA #3 might be a suitable choice. AL383, with its higher strength, is better suited for parts with thicker walls or higher structural demands.

Cost Considerations: Compare the costs associated with each alloy. The pricing of different alloys can vary based on availability, demand, and manufacturing processes. Consider your budget and assess whether the performance benefits of one alloy justify any cost difference compared to the other.

Industry Standards and Expertise: Check if there are any industry-specific standards or guidelines that recommend a particular alloy for your application. Additionally, consider the expertise and familiarity of your manufacturing team or supplier with each alloy. If they have prior experience with one of the alloys and possess the necessary expertise, it might influence your decision.

Comment below how much you think the ejector half of this Die Cast mold weighs.

At Simalex we make all of our tooling inserts from Heat treated H13, here's why.

H13 is a type of alloy steel that contains a combination of elements such as chromium, molybdenum, vanadium, and carbon. These alloying elements contribute to its desirable properties, including high hardness, wear resistance, and hot strength.

1.) H13 steel exhibits excellent hardness and wear resistance, making it capable of withstanding the high temperatures and abrasive forces involved in die casting. The tooling needs to withstand repeated thermal cycling and contact with molten metal, and H13's hardness helps maintain its shape and resist wear over time.

2.) H13 steel has high hot strength, which allows it to maintain its structural integrity and resist deformation even at elevated temperatures. This property is crucial in die casting, where the tooling is exposed to the intense heat of molten metal and needs to maintain dimensional stability

3.) H13 has good thermal conductivity, meaning it efficiently dissipates heat. This property helps to prevent localized hot spots in the die and promotes more uniform cooling of the casted part. Effective heat transfer is essential for achieving consistent part quality and minimizing thermal stresses in the tooling.

4.) H13 exhibits good toughness and impact resistance, which are important for withstanding the forces and stresses encountered during the die casting process. The tooling may experience high-pressure injections, rapid cooling, and mechanical stresses during ejection, and the toughness of H13 helps prevent cracking or fracturing.

Using a CNC machine for deburring die castings offers precise and consistent results, improved efficiency, and cost-effectiveness. CNC machines operate with high accuracy, ensuring uniformity across parts. They can work autonomously, reducing labor costs and increasing productivity. CNC machines handle complex geometries effectively, while manual deburring may struggle. Additionally, CNC machines provide a safer working environment, minimizing operator risks. Overall, CNC machines offer precise, efficient, and cost-effective deburring compared to manual methods.

Robots in die casting won't eliminate jobs but transform them. They enhance efficiency, precision, and safety, working alongside human operators. People will still be needed for skilled tasks like programming, maintenance, quality control, and decision-making. The collaboration between humans and robots will lead to increased productivity and new job opportunities.

Using a multi-cavity die-cast mold offers several significant benefits. Firstly, it enables increased productivity by allowing the production of multiple parts simultaneously, reducing manufacturing time and costs.

Simalex is ISO 9001 certified

ISO 9001 is a quality management system standard developed by the International Organization for Standardization (ISO) that specifies the requirements for a company's quality management system. The standard is designed to help organizations ensure that their products and services consistently meet customer and regulatory requirements.

To become ISO 9001 certified, a company must implement a quality management system that meets the requirements of the standard and undergo an independent audit by a third-party certification body. The audit evaluates the company's processes and procedures to ensure they meet the requirements of the standard.

ISO 9001 certification demonstrates that a company has implemented a robust quality management system and is committed to continuous improvement. It can help companies improve their processes, increase customer satisfaction, and gain a competitive advantage in the marketplace. Additionally, many customers and procurement organizations require their suppliers to be ISO 9001 certified as a condition of doing business with them.

At Simalex we expect each person that processes each part from casting to shipping, performs a quick visual inspection, this is one small part of our quality system, but the more eyes the better.

What are they looking for?

Surface finish: The surface finish of a die casting is an important visual indicator of quality. The casting should be free of any visible defects such as cracks, porosity, or other imperfections. The surface should also be smooth and uniform.
Parting line: The parting line is the line where the two halves of the die meet. It should be visually inspected to ensure that it is clean and free of any flash or burrs. Flash or burrs can interfere with the fit and function of the part.
Casting porosity: Die castings can be prone to porosity due to the nature of the casting process. Porosity can weaken the part and reduce its overall quality. The casting should be visually inspected for any signs of porosity.
Structural integrity: The die casting should be visually inspected to ensure that it has the necessary structural integrity to perform its intended function. This can include checking for any visible signs of deformation or warping.

Overall, a visual inspection of a die casting should focus on ensuring that the part is free of defects, meets the required specifications, and has the necessary structural integrity to perform its intended function.

Vibratory finishing is a surface finishing process that involves placing parts in a vibrating bowl or tub filled with abrasive media and water or other compounds.

Die castings often require vibratory finishing to improve their surface finish, remove burrs, and improve their dimensional accuracy. During the die casting process, the molten metal is injected into the mold at high pressure, which can cause the formation of burrs or flash on the part. Vibratory finishing removes these imperfections and creates a smooth, polished surface finish.

Vibratory finishing also helps to improve the dimensional accuracy of die castings by removing any excess material or flash that may have formed during the casting process. This ensures that the part meets the required specifications and tolerances.

In addition to improving the surface finish and dimensional accuracy, vibratory finishing can also help to increase the fatigue life of die castings by relieving residual stresses that may have formed during the casting process. This is achieved by subjecting the parts to a controlled amount of vibration and media, which can help to remove any internal stresses and improve the overall strength of the part.

Overall, vibratory finishing is an important step in the production of high-quality die castings, as it helps to ensure that the parts meet the required specifications and have the desired surface finish and dimensional accuracy.

Here we are using our Doosan DNM 5700 with a Sam Chully 4th axis to interpolate this round casting for the military. Without the 4th axis we would need multiple set ups to machine all of the features on this part.

https://www.youtube.com/watch?v=KlRaz5GS3Vc

CUSTOM HIGH PRESSURE DIE CASTINGS | Simalex Manufacturing Co | Langley, BC Simalex Custom High Pressure Die CastingEFFICIENT high pressure Die CastingFrom Tool Design to FinishingWhen you work with Simalex, they become an integral p...

As you prepare to embark on a new adventure in Alberta, we wanted to take a moment to express our gratitude for all that you've contributed to our team. Your hard work, dedication, and positive attitude have made a lasting impact on everyone here.

We're sad to see you go, but we're excited for the opportunities that await you in your new home. We know that you'll excel in whatever you do, just as you have here. Your talents, insights, and dedication will be missed, but we know that you'll make a positive impression on everyone you meet in Alberta.

Thank you for everything, Cole. You've made a difference in the lives of everyone you've worked with, and we wish you all the best in your new chapter.

Simalex Then & Now!

We are a family owned and operated business that was founded by Alex Lyhne and George Simon Wentworth in 1964. Interestingly, the company got its name from the two founders. The name was created with ‘Sim’ from ‘Simon’ and ‘Alex’ — to get 'Simalex'.

Fred Lyhne, Sr. then became a partner soon after and passed the torch onto his son, Fred Lyhne, Jr., who currently leads our team of die casting design and engineering experts.

As a Simalex client, you’re working with some of the most talented die casters and CNC machining experts in North America while getting exceptional value for your money.

See for yourself by choosing Simalex for your next custom high pressure die casting project!

Here is a close up of a part that is being is cast, ejected & extracted from a die casting machine.