In manufacturing, some projects are important. Others are mission-critical.
When demand for ventilators surged during a national emergency, Twin City Die Castings was called upon to produce precision die-cast components for a life-saving medical device program. The challenge wasn’t simply producing parts quickly. The company needed to scale production dramatically while maintaining the quality, consistency, and dimensional integrity required for medical applications.
The Challenge: Increasing Throughput Without Sacrificing Quality
Twin City Die Castings, a long-standing manufacturer of precision aluminum and magnesium die castings, was selected to produce thirteen unique cast components used in ventilator assemblies. The project required thousands of parts to be delivered on an aggressive timeline, with no room for quality issues or process delays.
The finishing operation presented a particular challenge. Parts required a clean, uniform surface finish suitable for medical device applications while preserving dimensional accuracy. The company wanted to use steel media to achieve the desired results, but needed equipment capable of handling the demands and weight of steel media processing.
Facing an accelerated production schedule, Twin City Die Castings needed a proven finishing solution that could be implemented immediately.
The Solution: Rapid Testing, Process Optimization, and Proven Equipment
With decades of experience using ALMCO equipment, Twin City Die Castings turned to ALMCO for support.
The collaboration began with immediate application testing to evaluate finishing performance and establish process parameters. Using an ALMCO OR-9VLR Vibratory Round Bowl Finishing Machine, the teams tested parts with steel media to determine the optimal finishing approach.
Early trials achieved the desired surface finish, but some components experienced distortion during processing. Rather than accepting a compromise, the teams worked through machine settings and process variables, fine-tuning operating conditions until they achieved both cosmetic and dimensional requirements.
Once the process was validated, Twin City Die Castings moved quickly. Equipment was secured, tooling was developed, and production-ready parts were being processed in a matter of days. The company installed and brought the finishing system online on an accelerated timeline, helping it meet demanding production requirements.
The Results: Reliable Production Under Extraordinary Circumstances
With the finishing process established, Twin City Die Castings successfully supported the production of tens of thousands of ventilator assemblies during a critical period.
The project demonstrated the value of combining application expertise with dependable finishing technology. The optimized process delivered the required surface finish while maintaining part geometry, allowing production to proceed efficiently and consistently throughout the program.
Just as important, the equipment performed reliably under the heavy demands of steel media processing. The project reinforced the role that robust finishing systems play in keeping production moving when deadlines are measured in days rather than months.
The success of the ventilator program ultimately earned industry recognition and showcased what is possible when manufacturers, suppliers, and equipment partners work together to overcome complex production challenges.
Why It Matters
When manufacturers face compressed timelines, demanding surface-finish requirements, and zero tolerance for inconsistency, success depends on more than equipment.
It requires a partner that can help validate processes, solve application challenges, and deliver reliable performance when it matters most.
For Twin City Die Castings, ALMCO provided the testing support, process expertise, and finishing technology needed to transform a difficult production challenge into a successful outcome, helping keep a critical supply chain moving when it was needed most.
Whether you’re finishing medical components, aerospace parts, automotive castings, or industrial hardware, ALMCO works alongside manufacturers to develop proven finishing solutions that improve quality, increase throughput, and support production success.
