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Aluminium PDC & GDC Component fettling

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Operator fatigue and injury associated with the high heat environment and the smoke inhalation can be avoided by deploying robots. Typical cycle times of 6 -7 seconds can be achieved for extraction. Based on the machine cycle time which is around 45s, the robot can be utilized for quenching, trimming press loading and in some cases for runner and riser cutting using a cut off saw.

Since the robot consistently unloads in around 6-7 seconds, a significant productivity improvement is registered. Energy costs are reduced as the machine idle time is reduced. The peripheral equipment such as the holding furnace and the melting furnace have to operate for less time producing more components. These are some of the indirect cost savings while deploying robots.

Several industries such as automotive, lighting, household appliances and pharmaceutical equipments use aluminium PDC components. In the die casting industry, robots can be used in the following areas

  • PDC extraction
  • Die Spraying
  • Insert placement
  • Secondary operations such as gate presence checking, quenching and trimming

BENEFITS OF ROBOTIC TENDING

  • Increased workplace safety for operators and reduced exposure to hazardous fumes and heat
  • More than 25% increase in productivity on off shifts and
  • 15-20% energy savings due to increase in OEE of the melting and holding furnaces
  • Less heat loss from the dies between cycles leading to reduced scrap
  • Easily reprogrammable to accommodate component changes
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SUCCESFUL PROJECTS
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YEARS OF EXPERIENCE

Industries Served

  • Personal Care Products

    Personal care products require unique bottle shapes and multiple bottle sizes to be run from the same filling lines. PET - Plastic Extruded Squeeze tubes of various shapes and sizes can also be accommodated

  • Home Care Products

    Our systems can handle PET, HDPE, PP and PVC containers with or without handles

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FREQUENTLY ASKED QUESTIONS

Aluminium PDC and GDC component fettling automation uses robots to remove flash, burrs, gates, and excess material from cast aluminium parts. It replaces or reduces manual grinding and trimming in foundry finishing operations.
Robotic fettling can improve operator safety, reduce fatigue, and deliver more consistent results than manual finishing. It is especially useful where parts are repetitive, high-volume, or too hazardous for prolonged manual grinding.
Robotic fettling is typically used for aluminium pressure die cast (PDC) and gravity die cast (GDC) components that need gate removal, deburring, trimming, or surface finishing. The best fit depends on part geometry, flash location, and production volume.
A robot handles the casting and uses tools such as compliant deburring spindles, grinding wheels, or carbide burs to remove unwanted material. The process can be integrated with inspection, part handling, and safety guarding for a complete cell.
The main benefits are improved safety, higher consistency, better productivity, and reduced operator strain in harsh foundry conditions. It can also support longer runtime and more predictable output than manual finishing.
Yes, when the cell is engineered with proper guarding, interlocks, emergency stops, and safety controls. Synapse Robotics states that its robotic solutions are engineered with full safety compliance, which is important for cells accessed by operators and maintenance staff.
Deburring usually refers to removing smaller burrs or sharp edges, while fettling often includes heavier material removal, gate cutting, and finishing on cast parts. In practice, the two overlap in foundry automation and may be handled in the same cell.
The exact gain depends on part type, cycle time, and cell design, but robots can provide more consistent throughput and reduce idle time caused by manual handling. For many foundry applications, the real value comes from stable output and lower scrap risk rather than just speed.
Common tools include compliant deburring tools, belt grinding tools, pedestal grinding setups, and tungsten carbide burs. Tool choice depends on the material, flash thickness, and surface finish required.
Yes, robotic fettling cells are usually customized around the casting geometry, clamping method, tool path, and production rate. A good system design starts with sample parts and process data so the cell matches the real application.
You typically need part drawings, photos, cast material details, flash locations, target cycle time, annual volume, and any quality or safety constraints. This helps define robot size, tooling, fixture design, and cell footprint.
Yes, a robot can follow repeatable paths and apply more consistent force and motion than manual grinding. That usually improves repeatability across shifts and reduces variation caused by operator fatigue.