Break The Mold
Infrastructure
Our infrastructure seamlessly connects every aspect of concept-to-product development, manufacture, and rigorous testing, utilising the latest machinery, equipment and most advanced CAD/CAM/Simulation software. This integrated approach ensures every product benefits from reduced lead times, improved quality, and optimised performance.
Product Development
More than 25 GB of data go into the design and development of every product.
- Each casting commences with the development of accurate 3D models
- Backed by simulation expertise in more than 2500 castings
using MAGMA Soft & Nova Cast - Machining simulations get executed with precision using
EDGE CAM & MASTER CAM - Additional facilities include CMMs, FARO 6-Axis Scanner among others
Molding
Magna has two molding lines to address varied customer requirements.
- IMF Furan line for large castings of 50 to 250 kgs with a capacity of 10 molds per hour. Match Plate Size – 1200 mm x 1000 mm x 350/350 mm.
- Hunter high-pressure green sand molding line for small-to-medium castings of 1 to 20 Kgs with a capacity of 70 molds per hour.
Match Plate Size – 600 mm x 500 mm x 215/185 mm. - 3D-printed cores and molds make complex castings precise and effortless.
Sand Treatment
- Sand is first pre-processed sand before being routed through high-end mixers for the core shop and molding lines.
- Secondary sand cooler mechanisms are used for optimal molding conditions.
- Thermal reclamation ensures high recyclability of the sand.
- World-class standards of sand treatment.
Core Shop
The core shop offers unique capabilities:
- Time-tested Coldbox core process.
- All core compositions and settings are stored and retrieved instantly via a central server.
- RFID-enabled machines for perfect, precise and repeatable cores.
- Shell cores
- 3D-printed cores and molds.
Melting & Testing
The raw material that goes into the making of every casting matches the highest quality benchmarks, with 3 medium frequency induction furnaces
@ 3 tons per hour supply to both molding lines. Vital parameters such as metal composition, temperature and quality are tested.
- Advanced Thermal analysis (ATAS), Spectrometers, Leco Carbon-Sulphur determinator, radiation pyrometer, image analyser and others guarantee
high metal quality. - Comprehensive mechanical and impact testing
Fettling & Finishing
Magna has a dedicated finishing division @ 35000 Sq ft in a dust-controlled environment with independent cells for each product line, ensuring timely output and superior finish.
- Special Purpose Machines (SPMs)
- CNC fettling machines
- High speed grinders using Diamond coated tools
- Grit blasting
- Paint booth
Machining
Infrastructure includes a wide range of CNC machines, multiple CMMs, honing inspection, profile scanners and boroscopes to ensure world class machining.
- 5 axis machines
- Multitasking machine – Integrex
- 4 axis machines
- Horizontal and vertical machining centres
- Vertical turnmill centers and Horizontal turning centers
- Honing machine
Value Added Services
- Painting
- Phosphating
- Powder coating
- Comprehensive leak testing (Pressure range: 6 to 35 bar)
- Millipore testing for cleanliness certification
