Sand Casting

Consistent, Porosity-Free and On-Time Castings

Sand Casting Services

LeClaire Manufacturing in Bettendorf, Iowa casts and machines simple to complex aluminum sand castings and permanent mold castings. With a focus on automation of our manufacturing processes and controls, we lead the foundry and machining industry in quality, consistency and on-time delivery of aluminum sand casting and machining.

Why Choose LeClaire as Your Aluminum Sand Casting Foundry?

  • We’ve been serving the industry since 1966.
  • We emphasize quality craftsmanship.
  • We’re family owned and operated.
  • We are ISO 9001:2015 certified.
  • We have a just under 300,000 sqft of production space in the heart of the Midwest.

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Aluminum Sand Casting by LeClaire Manufacturing

Engineering Expertise

Our in-house automation team consistently sets industry standards by implementing controls, deploying robots, and advancing technological innovation in aluminum sand casting. This commitment to engineering excellence is leveraged throughout our foundry and machine shop to provide you with operational scale rare among aluminum foundries.

A Steady, Reliable Supplier – a Dependable Partner in Aluminum Casting

LeClaire’s strategy of diversifying our customer base and pursuing controlled strategic growth provides us with extraordinary financial stability. At a time when other aluminum foundries are looking for answers, LeClaire has a proven track record of sustainability to meet your sand casting needs now and in the future.

We Reinvest in Our Business, and You Benefit

Year after year, we invest our profits back into our business. This reinvestment means you get access to modern molding equipment, real-time x-ray technology, advanced robotics, CNCs, CMMs, and more. We’ve expanded our foundry to increase capacity, and we’ve improved our processes to deliver consistent, porosity-free quality in aluminum castings and 98% on-time delivery.

Aluminum Sand Casting Applications

Aluminum sand castings has applications in a wide range of industries, including aerospace and defense; agriculture; automotive; energy; marine; medical; mining; and fluid management. Below are some of the applications of our casting services across leading industries.

Aluminum Sand Casting for Consumer Goods

From appliance parts to aluminum cookware to lawncare equipment, LeClaire’s sand casting capabilities are a perfect fit for the consumer home goods industry. Leading manufacturers of merchandise found in marine engines, motorcycles, snow mobile, and grill bodies turn to LeClaire’s for aluminum casting services.

Aluminum Sand Casting for Agriculture

Agriculture applications for our casting capabilities include measuring and control devices, valves, and field equipment parts. Our sand casting services are up to the challenge of manufacturing parts for pickers and spreaders, ag waste removal equipment, tractor parts, and other farm equipment.

Sand Casting for Military/Defense Applications

We are proud to serve customers in the defense industry. From helicopter parts to flight control equipment, from missile launch technology to Special Ops field equipment, the military applications of our casting capabilities are wide-ranging.

Benefits of Aluminum Sand Casting

  • Aluminum is a light weight and strong material
  • Readily available raw material
  • Provides a smooth finish
  • It’s a cost-effective casting process
  • The simplest and most versatile aluminum casting method
  • High degree of tooling flexibility to accommodate design changes
  • Ideal for manufacturing scale-up
  • Ideal for low production applications

Green Sand Casting Equipment

At LeClaire Manufacturing, our sand castings are made using automatic green sand molding machines. Green sand is mixed with clay and water to obtain the desired characteristics. The mixed sand and clay is then automatically measured, and then pneumatically blown, against the pattern. Hydraulic rams compact the sand against the pattern, the mold then enters the production belt line, where the molten aluminum is poured using robotic ladling. Our fully automated green sand molding machines and our robotic ladling system enable us to achieve predictable and repeatable results.

Tooling

Utilizing dedicated and certified mold flow Software Engineers, LeClaire Manufacturing utilizes computer “Casting FEA” simulations on all new tools we build. This advanced technology identifies problem areas, or porosity probability, before the tool is made. This ensures our customers receive the castings they require, to the specification they require. Our software simulations are conducted and analyzed by a certified user, one of only 29 certified Simulation Engineers in the U.S. today.

Core Making

LeClaire Manufacturing makes all cores in-house. The use of multiple types of core-making machines allows us to meet each specific core’s requirement. Our ability to make complex cores and turn out a quality casting separates us from our competitors. From a single cylindrical core to complex eighteen piece core assemblies, LeClaire Manufacturing has the experience and expertise to make your design a reality.

Metal Pouring

Selecting the correct aluminum alloy for your casting is critical to the quality of your part. LeClaire has experience pouring a wide variety of metals depending on our customer’s specific needs. After 50+ years of pouring 200, 300, 500 and 700 series aluminum alloys, we are experts in selecting the right aluminum alloy for your specific project needs.

Heat Treating

There is no room for error in heat-treating. Accurate controls yield predictable results. Utilizing drop bottom heat treat systems, as well as ‘a system worth visiting LeClaire for’, our experience and expertise in maximizing mechanical properties and efficiencies thru heat treat is extensive.

Mechanical Properties

Achieving the desired mechanical properties is accomplished through a combination of alloy selection, heat treat cycle time, aging cycle and, in some cases, additives to the metal. Our decades of alloying experience help us to meet the desired mechanical properties.

Meeting our customers’ mechanical property requirements is critical to our customers’ parts — and our success as well. Our in-process mechanical property testing ensures we meet or exceed each customer’s specific project requirements, no matter how challenging.

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Why Do Customers Prefer LeClaire Manufacturing?

“No foundry I know of does as complicated of parts, as consistently, as LeClaire.”

Vice President, Aluminum Casting Engineering Software Company