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CAPABILITIES

Creating Solutions from Concept to Reality

We specialize in the design and manufacture of highly engineered aluminum products that require high end casting, precision machining, assembly, and superior testing capabilities. While we specialize in thermal solutions we also use our core competencies for non-thermal applications. Our thermal products are comprised of heating elements, tubes or other components which are cast into an aluminum form (“cast-in products”). We create engineered parts which produce heating, cooling, or both, for specific applications. Our solutions utilize cast and non-cast technologies to make parts out of aluminum and a variety of other materials. Our non-thermal products are made with the same engineering and manufacturing expertise. Our 54,000 square foot facility in Batavia, Illinois houses a state of the art foundry, CNC mills and lathes, plus a variety of testing, assembly and inspection capabilities.

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Engineering Expertise

TEMPERATURE UNIFORMITY EVALUATION USING FINITE ELEMENT ANALYSIS (FEA)

Engineering Expertise

The CAS Engineering team possesses extensive technical knowledge with decades of experience in design and manufacturing. The ability to design “heated parts” with excellent temperature uniformity is one of our specialties. Our engineering capabilities include Computer Aided Design (CAD), 3D modeling and Finite Element Analysis (FEA) services.

Our engineers are also intimately familiar with the applications and markets where our products are used, including applicable industry standards and regulations. We have a long history of working closely with our customers engineering teams to develop the most effective product at the lowest cost.

Speed to Market

PRODUCT SOLUTION FOR SOLVENT HEATING - FROM CONCEPT TO REALITY

Speed to Market with Quick Turn Prototypes

Moving a product from concept to reality is vital. The CAS New Product Development (NPD) process enables our customers to achieve their goal of delivering new products to market with speed. Our cross-functional team of engineers and technicians adhere to robust and proven processes.

We have many options at our disposal to quickly produce castings for prototypes. Concepts and ideas are routinely validated by trial runs and lab testing, and all prototypes are thoroughly inspected for conformity to specifications. As a result, our customers receive new products which meet or exceed expectations on time. Our NPD process includes meticulous documentation which facilitates a seamless transition to production.

Operational Excellence

PARTS ARE MACHINED WITH THE TIGHTEST TOLERANCES AND PRECISE MEASUREMENTS USING CNC MILLS AND LATHES.

Operational Excellence

CAS operates a state-of-the-art manufacturing facility. The cast-in process begins with heater elements or tubes, which are precisely formed by our technicians using proprietary fixtures and tools assuring part-to-part repeatability. Our engineers and casting experts design mold tooling to control the casting process for optimal metallurgy.

Our aluminum foundry features proprietary low-pressure cast technology. We also use the traditional gravity pour method for parts which are better suited to this process. Parts are machined to the tightest tolerances using computer numerical controlled (CNC) mills and lathes, with critical dimensions checked by coordinate measurement machine (CMM) to the hundred millionths of an inch. Our assembly capability includes electrical test and assembly, welding and brazing, cleaning and packaging. We maintain a class 10,000 positive pressure clean room for specialty applications.

 

Products and Markets

The Cast Aluminum Solutions product line offers a variety of solution approaches to the marketplace. Our engineered products give customers maximum flexibility to flawlessly integrate our parts into their equipment or systems. The flagship of our line is the cast-in heater, typically an aluminum part. We also make non-cast products such as the Interference Fit Construction (IFC) using our proprietary manufacturing process to install heater elements into wrought metal alloys. An off-the-shelf solution for liquid and gas heating is provided by our CAST-X family of circulation heaters. Standard aluminum platens offer a ready-made product for 200mm and 300mm silicon wafer processing. Cast Aluminum Solutions is a leading component supplier to the food service, semiconductor process, and medical equipment markets. We also service other markets including packaging, adhesive, plastics extrusion, factory infrastructure equipment, and aerospace systems.

Medical

Medical

CAST-IN HEATED PART FOR BLOOD ANALYSIS

Food

Food

HEATED LINERS FOR FOOD WARMING PANS

Clinical Lab

Clinical Lab

TURNKEY CAST ALUMINUM HEAT EXCHANGER FOR A DNA ANALYSIS MACHINE

Packaging

Packaging

CAST-IN ALUMINUM HEATER USED FOR SEALING LIDS ON FOOD CONTAINERS

 

Semiconductor

Semiconductor

WAFER PROBING PLATEN DELIVERS BOTH HEATING AND COOLING FUNCTIONS TO A PRECISION MANUFACTURED PART

Paint Spray

Paint Spray

CAST-X 2000 FAMILY OF CIRCULATION HEATERS IMPROVES VOLUME, FLOW AND PRESSURE

Value-Added Services

FULLY ASSEMBLED AND TESTED PART INCLUDING REFLECTOR PLATES, WELDED FLANGE, ELECTRICAL TERMINALS AND TEMPERATURE SENSORS

Value-Added Services

CAS takes pride in offering our customers one-stop shopping for “turn-key” solutions. We are able to deliver additional services through a vast network of expert suppliers. These include coatings like Teflon,® hardcoat anodize, alodine; platings such as electroless nickel and gold; joining through vacuum furnace brazing, electron beam and laser welding; and special part cleaning and packaging for delivery to medical or semiconductor clean room environments.

 

Quality and Continuous Improvement

CRITICAL DIMENSIONS CHECKED BY COORDINATE MEASUREMENT MACHINE (CMM)

Quality and Continuous Improvement

A commitment to quality and continuous improvement permeates our company. We have an American Society for Quality (ASQ) Certified Six Sigma Black Belt on staff leading the way. CAS takes great pride in the achievement of having earned the internationally recognized ISO 9001:2008 certification for quality management and quality assurance. We constantly strive to increase efficiency and add value by using Lean Manufacturing as part of our Continuous Operational Improvement (COI) efforts.

 

 
 
 

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2012 M

Inc. 5000

Manufacturer of the Year 2015
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