Operational Capabilities
At Mega Metals, we take pride in our advanced melting capabilities, which are pivotal to producing the high-performance alloys that our clients rely on. Our state-of-the-art melting facility boasts a capacity of over 1,000 tons annually, allowing us to handle a wide range of aluminium alloys with efficiency and consistency. Our melting process is designed to meet the stringent demands of diverse industries, ensuring that every batch meets the highest standards of quality. We understand the importance of Alloying, hence our dedicated and vastly experienced chemist makes sure each Al Grade is processed systematically.
Quality Assurance
• Chemical Composition Analysis: To verify that the alloy meets the specified formulation.
• Mechanical Property Testing: To ensure that the final product performs as expected under various conditions.
• Continuous Monitoring: Throughout the melting process to maintain optimal quality.
Sustainability
We are committed to sustainable practices in our melting operations. Our facility emphasizes energy efficiency and waste reduction, contributing to our goal of minimizing our environmental footprint.
APCM with a 30M chimney – Minimising harmful gases emissions
Dross machine For maximum recovery of metal
Mega Metals is an end to end solutions provider for all Aluminium Die Casting and Sub-assembly components for Automotive & Non-Automotive Components for both domestic & export markets.
Our highly efficient and effective Aluminium Casting Solutions allows us to cater to numerous product category such as Suspension clamps, heat sinks, automotive housings, Clutch systems, Heavy Industrial Motor End-Covers.
Our experience with HPDC with the future plans of incorporating automation across all manufacturing processes, and cutting edge technology enables us to cater to precision components across various sectors in the ever growing market.
Silent features:
• High speed Cycle time – New age technology combined with our team’s expertise we are providing high productivity castings.
• Advance Cooling Systems - Control temperatures, reduces cooling time, and improves casting quality and machine efficiency
• Integrated Die Management – systems to reduce changing die turnover, reducing setup times and improving overall productivity.
• High Energy efficiency – Special focus on reducing energy consumption and operational costs, contributing to a more sustainable manufacturing process.
HPDC Info:
At Mega Metals, we pride ourselves on delivering exceptional precision in every component we produce. Our advanced casting machining capabilities are a cornerstone of our operations, utilizing cutting-edge technology to achieve unparalleled accuracy.
Our Machining capabilities through a wide range of advanced machining equipment helps us to transform our high-quality castings into precise, finished components:
Silent features:
Precision is the hallmark of our machining operations. At Mega Metals, we achieve an impressive accuracy range of 2 ~ 5 microns. This level of precision is crucial for applications where exact measurements and tight tolerances are essential.
• High Precision: Our commitment to accuracy means that each component meets stringent specifications, ensuring fit and functionality in complex assemblies.
• Advanced Calibration: We use sophisticated calibration techniques and equipment to maintain and verify our machines' accuracy.
• Quality Control: Rigorous quality checks and inspections are integrated into our production process, ensuring that every part meets or exceeds our high standards.
Our commitment to quality in aluminium high-pressure die casting (HPDC) is the cornerstone of our reputation and success. We pride ourselves on delivering products that meet the highest standards of precision, durability, and performance.
Precision Engineering
Our process begins with meticulous design and engineering. Using advanced Computer-Aided Design (CAD) and simulation tools, we create detailed, accurate models of components to be cast.
We utilize state-of-the-art high-pressure die casting machines that inject molten aluminium into precisely engineered moulds with exceptional speed and accuracy. This technology ensures consistent wall thickness, fine surface finishes, and complex geometries.
Quality control is embedded throughout our production process. We employ a range of inspection techniques, including:
• Dimensional Checks: Ensuring components meet design specifications using advanced measurement tools.
• Material Analysis: Testing the chemical composition and mechanical properties of our aluminium alloys to confirm they meet or exceed industry standards.
• Non-Destructive Testing (NDT): Utilizing methods such as X-ray and CMM to detect internal defects without damaging the components.
Our quality control team conducts regular audits and reviews to maintain stringent standards and address any potential issues promptly.
Silent features:
At Mega Metals, our Engineering Department stand at the forefront of innovation in the aluminium die casting industry. These integral teams are dedicated to transforming concepts into high-quality, precision-engineered components that meet the exacting demands of our diverse clientele.
The Engineering Department is the backbone of our production capabilities, combining technical expertise with cutting-edge technology to deliver exceptional aluminium die casting solutions. Our engineers are skilled in every aspect of the die casting process, from initial design through to final production. It’s where creativity meets technical precision. Our team of designers and CAD specialists are responsible for transforming client requirements and conceptual ideas into detailed, functional designs that are ready for die casting.
Tool Management:
Tool Room is dedicated to the maintenance, development and optimization of the dies and tooling that are essential for producing high-quality aluminium components. Here’s an overview of how our Tool Room contributes to excellence in die casting.
With 17 years of dedicated experience and a robust presence, we are poised for transformative growth. As we set our sights on expanding our reach further into the European and American markets, we are thrilled to introduce the ground breaking advancements that will define our future.
• Machine Tonnage upto 1200 T for catering to more complex castings for intricate markets
• Promoting and implementing renewable energy to power facilities
• Innovation in material science is central to our strategy
• Introducing new machinery in Tool manufacturing processes and inhouse simulation software.
• Continuous automation through processes
• Strengthening our global network by forging strategic partnerships
We are excited about the future and the opportunities it holds. As we embark on this next phase of growth, we remain steadfast in our commitment to innovation, quality, and customer satisfaction.
