explore our services

Appalachian Cast Product’s vision is to be a turn-key option for our customers. This includes cast, trim, machine, and many other value added operations. We strive to supply our customers with a complete component and/or finished goods part.

Appalachian-Cast-Products-Thermal-Part-Image

Technical Services

There is no substitute for experience. At Appalachian Cast Products, our team brings over 150 years of combined expertise to deliver reliable, end-to-end die casting solutions.
We produce high-quality castings on time and at a competitive cost through advanced equipment and efficient, cell-based manufacturing—ensuring consistency, repeatability, and performance.

Our capabilities are supported by:
Process Control – Shot monitoring drives process stability and efficiency
Quality Assurance – Training and procedures focused on exceeding customer expectations
Metrology – CMMs, X-ray, and hard gauging ensure conformance to specifications
Tool Design – Magma mold-flow analysis optimizes tooling and process development

While automation continues to advance, our success is driven by the people who control and continuously improve the process.

Metal Processing

The foundation of good casting is how the metal is processed. At Appalachian Cast Products, we have a state-of-the-art Striko stack melter system that supports 8,200lb/hour.

In addition to the central melt system, each of our 12 die cast cells is equipped with its own dedicated holder/melter furnace. These individual furnaces provide approximately 500 lbs per hour of melt capacity, allowing us the flexibility to run multiple alloys across different die casting cells.

Die Casting

Die casting is the core of what we do. Appalachian Cast Products operates 12 die cast cells, with machine sizes ranging from 600 to 1,200 tons. Our die casting facility encompasses 34,000 sq. ft. and is designed to support efficient, high-quality production.

Our equipment includes three 600-ton machines, seven 800-ton machines, one 1,000-ton machine, and one 1,200-ton machine. Two of our die cast cells are fully automated, state-of-the-art robotic cells. In addition, we maintain strategic partnerships that expand our capacity to include higher tonnage machines up to 3,000 tons.

This combination of in-house capability and external partnerships provides optimal flexibility, maximizes output, and supports a wide range of aluminum alloys.

Metal Quality Assurance

Ensuring the quality of the metal is essential to casting integrity. At Appalachian Cast Products, the metal processed by our Striko stack furnace is degassed via lancing with dry nitrogen before delivery to the holding furnace. This process helps us ensure that the end products meet and exceed client expectations.

In addition to the added degassing step, we also perform a Spectrographic Analysis (assures the chemistry of the alloys), Hydrogen Absorption (measured using reduced pressure tests), and Metal Cleanliness (measured using a K Mold test) to ensure that only filtered and certified metals are used in all the products we cast.

CNC Machining Capabilities

ACP also has the capability to do numerous single point drilling and machining operations on dedicated machines. We have 9 vertical CNC (four are 4-axis machines), 1 horizontal CNC, as well as 3 turning centers.

Value Add and Finishing

To provide our customers with a full end-to-end solution, Appalachian Cast Products offers various processes needed to deliver a finished good. These processes include: powder coating, machining ultrasonic washing, cosmetic sanding, vibratory debur, shot blasting, T5 heat treat, impregnation, and assembly are available.

Tooling-and-Engineering-USA-Manufacturing

Tooling Capabilities

Our in-house tool room supports tooling design, repair and build. This allows ACP to do our own repairs and modifications, shortening lead times and minimizing down time.