Our Capabilities

FIND OUT WHAT’S POSSIBLE

If you can dream it, we can cast it.

No matter the industry, no matter the process, RMP has the capabilities to deliver your project on time and with industry-leading quality.

From casting and engineering to molding and design, read more about our capabilities and services below. And when you’re ready to start a quote, we’re here to guide you through the process.

Ductile Iron Production

Metal Poured:
65/45/12 As Cast, 80/55/06 As Cast, 60/40/18 Heat Treated
Capacity:
166+ Net Tons of Good Castings/Day
Casting Weights:
1# - 40#
Flask Size:
25.6”Wx21.1”H and 30.5”Wx23.6”H
Molding Machines:
Dismatic 240B and Dismatics MK5B
Core:
Laempe and Hottinger Core Machines (Isocure), Redford Core Machines (Shell)
Finishing:
AFS 75-Ton Trim Press (2), Sinto Barinder Autogrinder (4), Fox Grinders

Gray Iron Production

Metal Poured:
Class 25, Class 30, Class 35
Capacity:
70+ Net Tons of Good Castings/Day
Casting Weights:
1# - 40#
Flask Size:
14"x19" and 20"x24"
Molding Machines:
Disa Match, Hunter HMP 20XL (2), Brock
Core:
Laempe and Hottinger Core Machines (Isocure), Redford Core Machines (Shell)
Finishing:
AFS 75-Ton Trim Press (2), Sinto Barinder Autogrinder (4), Fox Grinders

Tooling and Design

At RMP, we take pride in offering our customers expert craftsmanship using the latest state-of-the-art technologies to design, model and construct all of the tools we use in our casting process.

Among the sophisticated technologies we employ are MAGMA and SolidWorks, two powerful and robust Computer Aided Design (CAD) software studios. We also use Markforged 3D printers for pattern and tooling setup.

All of this technology ensures that we have the tools, methods and procedures in place that are necessary to take our customers’ designs and make them manufacturable — producing the highest quality castings possible at competitive prices.

Induction Melting

RMP uses induction melting — a cost-effective and energy-efficient process for melting metal. This process produces much less dust and other pollutants than cupola furnaces.

We currently have five primary melting furnaces, each of which can produce three tons per hour. Three of these are channel induction furnaces and two are coreless induction furnaces.

Core Making

Cores are solid forms — usually made of sand — that are used to shape the internal cavities of castings. Hollow sections, undercuts and intricate geometries that cannot be achieved through conventional molding alone are achieved using cores.

There are multiple steps undertaken by RMP to successfully make quality cores, some using heat and some using chemicals. Additives and covering may be employed to enhance refractoriness — the ability of the core to withstand heat.

Green Sand Molding

Green sand molding is a cost-effective, fast and versatile way to produce molds. Compressing this mixture of sand transforms it into a hard mold that can securely contain molten iron. At RMP, this process is controlled by a highly-automated system to ensure consistency.

RMP uses two automated green sand molding technologies — vertical and matchplate. The patterns used in either process can produce hundreds of thousands of molds.

Vertical molding is mainly used for high-volume, high-precision casting due to its excellent efficiency and accuracy. However, it can also produce shorter runs efficiently (ductile iron molding).

Matchplate molding is primarily used for gray-iron molding. The process’s lower speeds and less expensive patterns are ideal for shorter series production.

Finishing

Casting finishing is the process of taking cooled, molded castings and preparing them for use by RMP customers. Some castings require additional finishing — either using automated grinders and trim presses or manual processes.

Shot-blasting may also be used to clean castings before they are finished by automated grinding.

Selecting the correct finishing procedure is volume-driven or based on customer quality requirements. Generally, parts are more refined with automated processes, but RMP still inspects every part after finishing and makes manual improvements as needed.

Inspection and Quality Control

RMP utilizes state-of-art technology on multiple CMMs to ensure accuracy. Our metrology lab uses laser-scanning technology that compares dimensions back to the original CAD drawings to be sure our final product fully conforms to plans, our metallurgical lab checks for proper physical and chemical composition and our full sand-testing capabilities ensure the proper moisture and clay levels and distribution of grain sizes for a consistent mold-making process.

RMP’s quality management system is ISO9001: 2015 certified.

Plant Engineering

RMP’s Plant engineers oversee the facility and all electrical, mechanical and control systems. They continuously work to integrate the latest industry technologies into our production processes and improve the plant’s efficiency.

Our engineers are also integral in the design of our facility’s expansion projects, working alongside electricians, architects and other craftsmen to enhance the capabilities of our plant.

These skilled professionals have a background in focus areas of mechanical, electrical, hydraulics, controls, environmental and industrial engineering.