INDEX:
Discover superiority in every aspect of your journey with us. From seamless delivery to uncompromising quality unparalleled customer support, Epcor Foundry sets the standard for innovation and reliability. Our commitment to timely delivery ensures your projects stay on track, while our unwavering focus on quality guarentees exceptional results every time. With dedicated customer support at your fingertips, you can trust Epcor Foundry to be your partner in success.
Experience the Difference,
Choose EPCOR Foundry for a journey defined by excellence.
Ready for a reliable partner from launch to production on new and transfer projects?
Questions about retooling or resourcing current aluminum casting programs?
NEW PROGRAM LAUNCH RISK ANALYSIS
Does your program meet these standards?
Contact us for solutions on retooling or launching your next project. Our Epcor Foundry team is ready to ensure unparalleled service to turn your concepts into reality.
Where others struggle, Epcor brings solutions!
No other aluminum sand foundry understands complex aluminum castings like Epcor Foundry. We tackle the projects that others shy away from.
Epcor Foundry Brings:
We know how to keep your production up and running reliably every day.
We understand the unique challenges our customers face, particularly with higher levels of design complexity.
Epcor Foundry has the necessary engineering, quality, and customer service expertise to support your needs.
Let's talk about your challenges: Contact Us
Staying ahead of the curve is not just an advantage—it's a necessity. Epcor utilizes industry leading simulation software on each program launch.
Problem Solving at The Start
By visualizing the metal flow, cooling, and solidifying processes, we can anticipate and address potential challenges before they arise.
Cost and Risk Mitigation
By simulating parts upfront, we drastically reduce the risk and total costs across your program’s life.
Rapid Production Readiness
This analysis ensures quick turnarounds without sacrificing quality, helping you stay ahead.
We understand the importance of adaptability and quick response times in today's competitive market. Our state-of-the-art facility enables us to offer flexible production solutions. This allows us to cater to diverse volume scenarios, from low to high volume production requirements. With advanced technology and capabilities, we can handle customized and standard casting needs with the utmost quality and consistency.
Connect with us to discuss how Epcor Foundry can contribute to the success of your projects
At Epcor Foundry, we understand the unique challenges our customers face, particularly when it comes to higher levels of design complexity.
Whether you require pressure-tight applications, thinner-walled sections, or highly complex coring, our experienced team is ready to tackle these challenges.
We would be delighted to discuss how Epcor Foundry can contribute to the success of your projects.
Epcor is committed to continued capital investment in automation technology, process improvement, and lean manufacturing. This enables us to provide you with the highest-quality aluminum castings at competitive prices.
Our Program Management Includes
EQUIPMENT
Our DISA Match and SINTO molding machines are the most precise and technologically advanced, optimizing mold quality and uptime to provide you with an uninterrupted supply of castings to keep your production lines running. Our shorter lead times put castings in your hands sooner.
We have the resources to solve your casting challenge.
Our Key Perspectives
Quality:
IATF 16949:2016:2016 and ISO:9001:2015 certified, the automotive industry's most widelty used international standard for quality management.
Support:
Customer support and program management - We take pride in satisfying our customers' needs from the point of purchase order, project launch, and mass production.
Manufacturing:
Manufacturing of complex aluminum casting for various industries - highly-cored/pressure-tight applications.
Expertise:
Engineering support and expertise - in-house simulation and pattern division allows complete control and flexibility. This is important for our customers especially when timing and speed to market are critical factors.
YOUR TRUSTED SOURCE FOR QUALITY
At Epcor Foundry, our success comes from our high quality controls, an engineering team that is second to none, and our passion to make better parts at a lower price. Let us show you what manufacturing ingenuity is all about...come visit us in Ohio!
We Focus On Solving Your Manufacturing Needs With Highly Specialized, Application-based Solutions.
Part 1 – COMPANY BACKGROUND
The benefits of working with Epcor Foundry and our in-house tooling division are substantial and critical to partners across many different markets.
How can we help you with your project?
We have the solutions!
In the casting world today, we hear about many problems such as supply chain risks, lead times, and line down threats. Companies are on the move in search of a viable solution, but what steps need to be taken in order to make the best foundry decision for your company?
Part 2 - Does your foundry possess the automated processes and controls needed in today’s stringent manufacturing requirements
Epcor has solutions such as:
Thank you for trusting Epcor Foundry. Let's talk about your challenges!
We have the solutions!
In the casting world today, we hear a lot of keywords such as supply chain risks, time constraints, and line down threats. Companies are on the move in search of a viable solution, but what steps need to be taken in order to make the best foundry decision for your company?
Does your foundry have the necessary engineering, quality, and customer service expertise to support your needs?
Thank you for trusting Epcor Foundry. Let's talk about your challenges!
Part Four - Holistic Approach to Supplier Selection
What are key factors you consider when selecting an aluminum foundry as a partner? How do these factors mitigate risk and maximize a successful mutual relationship?
Contact Epcor and Let’s Win Together
Part Three – Why is Customer Service More Important Now Than Ever Before
Good foundry owners and leaders always demonstrate integrity with the decisions they make. Customers desire the opportunity to trust and succeed with companies they count on.
Contact Epcor and Let’s Win Together
Part Two – Leadership and Placement of Value on Human Resources
Contact Epcor and Let’s Win Together
Part One – Staying Ahead of Competition and Leading in Industry
Contact Epcor and Let’s Win Together
Your Trusted Source For Quality
Epcor Foundry is your low cost U.S. source.
At Epcor Foundry, our success comes from our high quality controls, an engineering team that is second to none, and our passion to make better parts at a lower price. Let us show you what manufacturing ingenuity is all about...come visit us in Ohio!
Let's Win Your Next Project – Together!
Three Generations of Aluminum Sand Casting Knowledge and Expertise Make Epcor Your Trusted Partner
What is the Epcor Advantage?
Have questions about reshoring aluminum sand casting work?
Is the timing right for a solid US-based alternative solution?
Epcor Foundry has the resources you need to make a successful transition, especially those challenging complex applications that aren’t for everyone. Whatever your industry, let us help you!
Epcor provides you with the best technical and human resources to accomplish your manufacturing goals
Tradition. Passion. Commitment.
No other US based aluminum sand foundry understands complex aluminum castings for the Pump & Valve, Filtration, Fuel Transfer and Heat Exchanger industries like Epcor Foundry. We tackle the projects that others shy away from.
We know how to keep your production up-and-running reliably every day.
Protect your investment with epcor
Program Management:
Our transparent launch operation keeps you informed so program management is one less thing you need to worry about.
We never stop producing quality components for you.
The importance of aluminum in automobiles and commercial vehicles is ever-increasing due to many industry advantages which include lighter weight, complexity and design flexibility. Regardless of your industry or product line, Epcor can offer you the standards you need from a supplier. Let us show you how!
Please contact us to discuss your specific needs.
Epcor Foundry is focused on technology, processes, procedures and systems that create castings that meet the highest standard of quality. Implementing automation makes better parts – a benefit you can count on.
EPCOR FOUNDRY AUTOMATED PROCESS CONTROLS
Robotics
Automated 5-Axis Robotic Sawing
Robotic Pouring
PLC based monitoring and control of the following processes:
Sand System: Screening, aeration and additions
Sand Production: Continuous sand testing
Knockout: Job-specific pressure and and timing controls
Shot blast: Part specific parameters
Following best practices for implementing automation is something we take seriously at Epcor. Industry 4.0 is about using the internet of things to create new ways to do things more efficiently. When deployed correctly, automation reduces waste and increases quality
Epcor Is Opportunity
Questions about retooling or resourcing current aluminum casting programs?
Faced with complex aluminum casting challenges?
Please allow our team to help you develop the solution right for your company!
VISION. TEAMWORK. UNITY. YOUR TRUSTED SOURCE FOR QUALITY
IATF 16949:2016 was published by the IATF and replaces the current ISO/TS 16949, defining the requirements of a quality management system for organizations in the automotive industry.
WHY THIS MATTERS
Achieving this level of certification means our customers are ensured that they are purchasing the highest quality parts from a manufacturer dedicated to defect prevention, reduction of variation, and waste in the automotive industry supply chain.
Pressure Tight/Leak Tight Requirements? Stringent Field Applications?
These are familiar terms in many US markets such as Heat Exchangers and Air/Fluid Filtration. Epcor is proud to be supporting numerous tier 1 and OEM customers on the most challenging casting applications in these segments
Diesel engines have always been critical in the toughest heavy and long haul applications. Now, diesel engines are gaining increased interest for their improved carbon emissions and fuel efficiency making them a welcomed addition to passenger vehicle and light-duty platforms.
Epcor is proud to be a critical part of this picture supporting numerous Tier 1 and OEM customers on the most challenging casting applications in this arena.
Tell Us What You Need!
Epcor understands the key components of a successful operation. Partner with Epcor and see why we are
YOUR TRUSTED SOURCE FOR QUALITY
Now more than ever, customers require a casting supplier to:
We are here to help YOU!!
Please contact us to discuss your specific needs.
As an experienced global leader in aluminum casting technology – we've tackled the projects that others shy away from while maintaining quality
What is the Epcor Advantage?
Our precision craftmanship for complex and highly cored leak-tight aluminum castings gives you the competitive advantage you need.
While many of you are working from home, we are here to help you with your new casting designs. The Epcor engineering team is here to provide solutions for some of your toughest challenges. Whether you need a second look at a complex aluminum casting or are looking to redesign an existing part - we can help.
While businesses are being disrupted globally, we can help you make the most of a slower period.
American Made, Globally Trusted
Thank you for your business and partnership and we look forward to assisting you through these unprecedented times.
Epcor expands its production footprint in the Electric Vehicle segment. Let us work with you to expand your Electric Vehicle market share.
At Epcor, we turn design challenges into opportunities. Our precision craftsmanship especially for complex and highly cored leak-tight aluminum castings is a skill that few can emulate. As we enter 2020, we will use our design and engineering skills to give you the competitive advantage you need for the highest performing aluminum parts.
We are your foundry of the future.
Happy New Year,
Dave Seilkop
Visit Epcor Foundry & Seilkop Divisions at Booth #506
Midwest Design-2-Part Show
November 6 & 7, 2019
Indiana Convention Center • Indianapolis, IN
Free Registration: Click Here
Epcor has an exceptional history of maintaining casting supply when tooling is transferred to us. Our integrated quality driven processes include an in-house tooling facility and adapter plates which allow your patterns to seamlessly fit our machines.
Epcor Foundry is ready to help you maintain an uninterrupted supply of castings to keep your productions lines running. Our diverse background, years of experience in tooling transfers, and strong history of financial stability are here to support you.
Stop accepting “firm maybes” from your current supplier regarding on-time deliveries.
When reliability counts, accept nothing less.
Epcor has an exceptional history of maintaining casting supply when tooling is transferred to us. Our integrated quality driven processes include an in-house tooling facility and adapter plates which allow your patterns to seamlessly fit our machines.
Challenge:
Designing a casting to meet your first time throughput requirements—out of the gate.
Process:
Epcor’s Engineering Team examines your casting with advanced simulation software to both guarantee results and craft out-of-the-box design solutions.
Result:
Shorter launch lead times, and better long-lasting casting.
Additionally, significant reductions in both internal scrap rates at Epcor Foundry as well as a reduction of external scrap at the customer are being realized.
Epcor is your team for fresh thinking. We challenge existing assumptions and then put our technology and processes to succeed where others fail.
Below is another example of our aluminum casting breakthroughs.
Challenge
OEM automotive company was plagued by housing components that failed due to leakage.
Epcor Solution
Step 1: We used simulation sofware to correct areas that had been causing problems.
Step 2: Our engineering team designed new tooling to cast a chill into the rotor core – allowing heavy sections to solidify without shrink prorosity.
Result:
Epcor eliminated leaking – 100%!
The harsh work environment in the foundry is like no other. It is exactly that demanding environment that has positioned foundries to be on the leading edge of robotic automation. All foundries contend with high temperatures and the inherent issues associated with pouring metal. Robots handle this in a repeatable fashion that makes the foundry more efficient, safer, and unfazed by the heat seen in production.
At Epcor, the benefits for adding robotic automation were considerable:
Robotic automation also provides us with the flexibility to change – as your part requirements change.
Have a question about reshoring aluminum casting work? Allow Epcor to show you our precision craftsmanship, especially for complex and highly cored leak-tight castings, used in several industries including automotive.
As the number of automobiles increases, manufacturers of aluminum parts will be called upon to make more complex high-tech lightweight parts to increase safety and last longer. For this industry, aluminum builds better vehicles. The importance of aluminum in commercial vehicles and cars is increasing due to the many industry advantages. While most people emphasize the lightweight benefits for increasing fuel economy and reducing emissions, we like to also point out that castings made from aluminum can be amazingly complex while also being cost-effective, strong and very durable. Look for more aluminum in each vehicle in the future, including the structure.
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Epcor Foundry, a division of Seilkop Industries, Inc., recently announced Jeffrey A. Miller as National Sales Executive, effective immediately.
For the past twenty-three years, Jeff Miller has held key management positions in casting and machining sales and is highly experienced working with our nation’s largest users of automotive and truck parts.
In this position, Miller will be responsible for account management, equipment quotations, and developing metal casting solutions.
“Jeff is a seasoned manufacturing and sales professional focused on developing successful aluminum casting solutions, especially for the transportation and truck industry. We look forward to his contributions and technical expertise to drive our Company’s goals into additional markets. We are pleased to have him onboard in this important position,” said David Seilkop, President of Epcor Foundry.
Miller is a graduate of Bowling Green State University with a bachelor’s degree in business.
American Made, Globally Trusted & Lowest cost
- Epcor Foundry is your low cost U.S. source and proud to be 100% designed, engineered, and manufactured in our Cincinnati, Ohio production facility.
Epcor's prototyping services lead to substantial cost savings. Read about our process to reduce prototype costs.
Read about Epcor's Preventative Maintenance (PM) program that focuses on prevention over detection.
Read about how Epcor designed a better performing super light and leak-free casting for high performance automobiles.
Read about how Epcor’s automated process control ensures castings are made of the highest quality.
Read about this Tier 1 automotive challenge that Epcor solved with a new gating system which eliminated leaks and scrap.
Epcor Foundry, a division of Seilkop Industries recently installed a combination dry hearth and wet bath aluminum melting furnace from The Schaefer Group.
This gas fired furnace delivers degassed and filtered metal to the casting line – which gives Epcor the cleanest metal possible. The end opposite the dry hearth has a degassing unit and a filter with two electric elements in the ladle well end of the furnace, to maintain temperature stability during production.
"The Schaefer Combination Furnace gives Epcor the ability to produce higher quality parts more efficiently,” said Dave Seilkop, president of Epcor Foundry. “The unique ability of this energy saving combination furnace to also reduce metal loss with cleaner metal makes this an ideal choice for our aluminum part production,” he added. Installing the best equipment means producing better products at less cost for our customers – it's that simple!
Like every “solution,” this one started with a problem. An unnamed foundry supplying exhaust gas recirculation (EGR) valves to an auto parts manufacturer could not fulfill the order, and that buyer urgently needed to find an alternative source for aluminum castings. Epcor Foundries in Cincinnati was awarded the business. Then, Epcor’s challenge was to get the new part into production quickly, avoiding the quality problems that the previous supplier faced.
Epcor used ESI Group’s QuikCast casting simulation software to evaluate the initial mold design. They were able to identify several areas where the simulation showed porosity would be a problem. Engineers ran a series of alternative mold solutions while adding risers to feed molten metal to compensate for shrinkage in critical areas of the mold.
Click Here to read the full article.