ASCENT is a fast-growing organisation engaged in the manufacturing of prototype castings, patterns and dies using cutting-edge technologies and state-of-the-art equipment. Established in the year 2009 under the visionary leadership of Kalyan D Bobade, the company has made rapid progress in the automotive sector and has earned the trust of leading companies across the world.
Our manufacturing processes are supported by the latest Computer Aided Design (CAD) as well as Computer Aided Manufacturing (CAM) equipment. We believe in providing our customers with comprehensive solutions. Our strength lies in understanding, assimilating and adapting to the needs of our customers and delivering optimum solutions on time.
We take great pride in offering tooling as well as casting expertise through our end-to-end solutions from the prototype stage to the final production.
We have on board experts with considerable experience in foundry industries and developing prototypes and pattern tooling. Our team boasts of some of the smartest engineering minds and our core competence is in converting ideas into prototypes and prototypes into actual production. With in-house expertise and technology, we have the ability to deliver turnkey projects and you can be rest assured of timely deliverables without compromising on quality.
ASCENT combines skill and experience along with technological know-how to produce models as well as secondary tooling in a matter of a few hours to a few days. Our decisive response to your prototyping and tooling needs can allow you to check the form, function and design of a new product.
Beside the latest in computer aided technology and computer aided manufacturing, we possess CNC machining expertise that can help in creating core boxes, patterns as well as finished machined castings. Our professional work practices, transparent communication and commitment to results allow our customers to enjoy lower costs and reduced development time.
- Prototypes & Small Batch Production
- Pattern Toolings
- Investment Castings for Regular Production
Design – Computer Aided Design (CAD)
Based on the files provided by our customers, we map and understand their needs and the manufacturing processes are chalked-out using 3D CAD data of the required casting. Pro-E is used for the mould designing. Our design engineers, with their core expertise in CAD can generate the data required for development of cores and segments needed for the moulds.
We have a design team possessing expertise in CAD, which is involved in communicating with the customers for generation of the initial solid model. Subsequent machining takes place through the addition of machining stock. By adding of gating as well as feeding systems the actual mould design is started. After splitting the mould and separating the cores, addition of core prints takes place and mould segments as well as cores are located with the interlocks. Following this, checking of the mould assembly is done for interference and fit. The interfaces we use include STEP & IGES file formats.
Through product engineering, we work in tandem with our customers to implement an idea into an actual product. The technological know-how, expertise and the experience possessed by our team promises high quality deliverables. Right from castings to prototypes to developing actual components, each process is seamlessly executed.
Planning / Concept Development
Planning and concept development are the cornerstones of any effective product/process development. Through constant communication with our customers, we understand the development objectives defined through different factors. These factors include functions, manufacturability, durability, stress as well as cost aspects. The design forecast allows for understanding of the potential costs involved in the project, and these are intricately discussed with the customers.
The aim while designing a product is not just to have a lightweight design, but one that is efficient as well as economical. Simulation helps in identifying the proverbial chinks in the armour by determining ways in which the products can be made more efficient. Our team of designers along with our cutting edge technology can tackle the challenges head on.
Simulation is the key to the quality of the products developed. The tools used for simulation include -
Delcam Power-mill used for machining: Through this, simulation machining processes are optimised, so as to ensure that errors do not occur when the castings are put through the machining. Power-mill helps in identifying faults in drawings, wrong CNC programs, wrong tools or tool paths and collisions in motion.
AutoCast-X used for mould filling and the solidification simulation required for casting process: This helps in improving the casting quality as well as predicting the material properties. This crucial tool helps in mapping of the production processes.
CNC Pattern Making
For pattern making needs, we first modify the 3D CAD data to meet the pattern making requirements. For traditional patterns, parting lines are determined and the draft angles as well as fillets are added.
ASCENT has a highly advanced in-house foundry that can deliver components within specified time limits to the customers. The induction furnace has a capacity of up to 150 kg allowing for quick processing and timely completion of several different projects at one time. The castings are shaken after pouring and cooling and are then cleaned. After removal of gating as well as feeding systems, the castings are ready to be heat-treated and inspected.
Extensive documentation is done using modern tools for the workflow processes.