AI Precision Manufacturing,
at Scale.
Astron is your manufacturing partner for precision parts. We use AI and software to improve design for manufacturability, cut costs, speed up lead times, and deliver consistent quality—built for scale production.
Manufacturing Excellence
Trusted by North American Industry Leaders
Industries We Serve
Our AI-powered solutions optimize manufacturing processes across key industries, delivering precision, efficiency, and competitive advantage.
Engineering Expertise
Our AI-powered platform combines decades of manufacturing expertise with cutting-edge technology to deliver unmatched precision and efficiency.
AI-driven Part Optimization
Our proprietary algorithms analyze your designs to suggest improvements that enhance manufacturability while reducing costs.
Advanced DFM Support
Design for Manufacturability analysis that identifies potential issues before production begins, saving time and resources.
Tolerance & GD&T Validation
Precision-focused analysis ensures your specifications are achievable and optimized for both quality and cost.
Smart Material Selection
AI-recommended materials based on performance requirements, cost considerations, and global availability.
Contract manufacturing expertise
As a contract manufacturer and supplier of record, Astron manages the entire production lifecycle, from process selection and tool development to quality validation and supply chain management. We deliver production-ready components that meet specifications at scale while assuming all production risk.
- LK HPDC machines (400T, 630T, 800T, 1500T)
- Shot control accuracy: ±0.05% of stroke
- Real-time data acquisition (27 parameters)
- Vacuum-assisted casting capability
- DMG Mori 3-axis and 5-axis CNC centers
- Positioning accuracy: ±0.003mm
- High-pressure coolant systems (70 bar)
- On-machine probing and verification
- Automated trimming and deburring
- Vibratory and shot blasting surface finishing
- E-coating (15-25 μm) and impregnation
- Heat treatment for T6/T7 tempers
Process Transformation Expertise
Our engineering team specializes in converting components originally designed for extrusion, machining, or welding into optimized high-pressure die cast (HPDC) or low-pressure die cast (LPDC) solutions. This transformation typically yields significant benefits in cost, weight, and performance.
Aluminum Alloy Selection
Our material science expertise guides alloy selection based on specific application requirements. Each alloy offers distinct advantages in mechanical properties, castability, and post-processing capabilities.
| Alloy | Si Content | Key Elements | Properties | Applications |
|---|---|---|---|---|
| A380 | 7.5-9.5% | Cu: 3.0-4.0% Fe: 1.3% max | Excellent fluidity, good machinability, moderate strength | Thin-walled housings, covers, electronic components |
| A360 | 9.0-10.0% | Mg: 0.4-0.6% Fe: 0.6% max | Good corrosion resistance, moderate strength, pressure-tight | Fluid-handling components, marine applications |
| A413 | 11.0-13.0% | Cu: 1.0% max Fe: 1.3% max | Excellent fluidity, good thermal conductivity, low shrinkage | Complex thin-walled parts, thermal-critical components |
| ADC12 | 9.6-12.0% | Cu: 1.5-3.5% Fe: 1.3% max | Good die-filling, strength, and pressure-tightness | Automotive components, structural housings |
Computational Manufacturing Intelligence
Our engineering processes leverage machine learning systems to enhance design for manufacturability (DFM) analysis and optimize production workflows. These systems operate as embedded engineering tools that complement and extend our engineers' expertise.
Geometric Analysis & DFM
- Feature extraction from B-Rep models - Geometric feature recognition algorithms identify manufacturing challenges such as undercuts, thin walls, and deep pockets.
- Supervised learning for manufacturability prediction - Models trained on historical production data provide quantitative manufacturability scores based on geometric features, tolerances, and material properties.
- 2D drawing interpretation using vision models - Computer vision algorithms parse engineering drawings to extract critical dimensions and GD&T requirements to validate manufacturability constraints.
Process Optimization & Control
- Unsupervised clustering of part families - Algorithms group similar components based on geometric and functional attributes, enabling standardized costing models and process parameters.
- Process parameter optimization - Gradient boosting algorithms recommend optimal die casting parameters based on component geometry, alloy selection, and required mechanical properties.
- Statistical process control automation - Anomaly detection systems monitor real-time production data to identify process drift before quality issues occur, maintaining consistent part quality.
High Pressure Die Casting (HPDC)
High-velocity, high-pressure injection of molten aluminum into water-cooled H13 tool steel dies. Astron operates LK HPDC machines from 400T to 1500T, producing complex near-net shape components with thin-wall sections and tight dimensional control.
Advantages
- Complex geometries with thin wall sections (0.5-2.5mm)
- High production rates (30-90 seconds cycle time)
- Excellent dimensional accuracy (±0.1mm typical)
- Superior surface finish (1-2 µm Ra)
- Part consolidation reducing assembly requirements
Design Considerations
- Higher tooling costs amortized over production volume
- Design must account for draft angles (typically 0.5-3°)
- Internal porosity must be managed for weldability
- Part size limitations based on machine tonnage
- Material selection constraints (A380, A360, A413, ADC12)
Typical Applications
- EV battery enclosure structural components
- Thermal management housings with complex cooling channels
- Electronic enclosures requiring EMI shielding
- Structural components with integrated mounting features
- Aerospace brackets and housings for weight reduction
Manufacturing Process Steps
Component & Tool Design
Parametric solidification simulation optimizes gate locations, overflow volumes, and cooling systems to minimize porosity and ensure complete cavity filling. Draft angles calculated per surface based on depth and texture requirements.
Technical Specifications
Alloy Preparation & Degassing
Precise alloy composition control via spectrographic analysis. Rotary degassing with nitrogen purge reduces hydrogen content below 0.1mL/100g to minimize porosity. Flux treatment removes oxides and enhances metal cleanliness.
Technical Specifications
Die Casting Process
Two-phase injection profile with first-phase filling at 0.1-0.5 m/s followed by second-phase intensification at 30-60 m/s. Statistical Process Control (SPC) monitors 27 parameters in real-time for quality verification.
Technical Specifications
Secondary Operations
CNC machining on DMG Mori 3- and 5-axis centers for critical tolerances. Secondary processes include shot blasting, impregnation for leak-tightness, and e-coating for corrosion protection.
Technical Specifications
Computational Fluid Dynamics
Simulate Before You Cast — Predict Flow, Eliminate Defects, and Launch with Confidence
Using high-fidelity simulation to validate casting designs before tooling, ensuring first-time quality and predictable manufacturing outcomes.
Complex Gearbox Housing HPDC
Metal flow analysis showing optimized fill sequence and venting for a complex A380 aluminum gearbox housing using HPDC process.
Simulation Results
Complex Gearbox Housing HPDC
Flow Analysis
Transmission Housing Thermal Gradient
Thermal Analysis
Cylinder Head Porosity Prediction
Porosity Analysis
True Digital Twins
Our simulation platform integrates directly with CAM workflows to create true digital twins of the manufacturing process.
Process-Validated Simulations
Correlation between simulation and actual process parameters exceeds 96%
Reduced Development Time
Visualize problems before cutting tool steel, saving 5-8 weeks in development
Defect Prediction & Elimination
Identify porosity, air entrapment, and thermal issues before production
Flow Analysis
High-fidelity metal flow simulations predict fill patterns, identify potential air entrapment, and optimize gate and runner systems.
- Magma HPDC Module
- Flow-3D Cast
- ESI ProCAST
Thermal Analysis
Thermal simulation predicts solidification patterns, identifies hot spots, and ensures optimal thermal gradients during crystallization.
- Thermal Profile Mapping
- Hot Spot Identification
- Cooling System Design
Defect Prediction
Advanced algorithms predict porosity formation, shrinkage cavities, and other potential defects before manufacturing.
- Porosity Prediction
- Shrinkage Analysis
- Air Entrapment Detection
Customer Case Studies
See how leading companies across industries have transformed their manufacturing processes with our AI-powered solutions.
Reduced Lead Time by 40%
A leading automotive manufacturer streamlined their precision component sourcing process, cutting lead times from 12 weeks to just 7 weeks while maintaining quality standards.
Achieved ±0.002" Precision
An aerospace components supplier leveraged our AI-powered quality control system to improve precision while reducing inspection times and rejection rates.
Lowered CNC Costs by 30%
A medical device innovator used our platform to optimize part design and material selection, dramatically reducing manufacturing costs while meeting FDA requirements.
Why ASTRON?
See how our AI-powered approach transforms traditional manufacturing sourcing with smarter, faster, and more cost-effective solutions.
ASTRON Approach
AI-powered Cost Optimization
Machine learning algorithms analyze thousands of manufacturing variables to recommend the most cost-effective approach for your specific requirements.
Comprehensive Quoting & Supplier Matchmaking
Receive accurate quotes within 48-72 hours, with thorough engineering analysis that matches your project to the ideal manufacturing partners in our verified network.
Data-driven Quality Assurance
Predictive analytics and real-time monitoring ensure your parts meet specifications with statistical process control and continuous improvement feedback loops.
Transparent Supply Chain Visibility
End-to-end tracking with real-time updates and proactive issue resolution ensures predictable delivery and reduces production risks.
Traditional Sourcing
Manual Cost Estimation
Relies on human estimation and negotiation, often leading to inconsistent pricing and hidden costs that emerge later in the production process.
Time-Consuming RFQ Process
Quotes can take days or weeks to receive, with lengthy back-and-forth communications and limited supplier options for comparison.
Reactive Quality Management
Quality issues often discovered late in production or after delivery, resulting in costly rework, delays, and potential field failures.
Limited Supply Chain Visibility
Minimal tracking capabilities with fragmented communication channels and reactive problem-solving when issues arise.
Manufacturing Presence
Strategically positioned facilities across North America providing rapid response times and local expertise for precision manufacturing.
Manufacturing Capabilities
Strategic manufacturing capabilities across North America for rapid response and specialized production.
Strategic Advantages
Local Expertise
Industry-specific knowledge
48-72 Hour Response
Rapid engineering analysis
OEM Proximity
Near manufacturing centers
Seamless Integration
Coordinated supply chain
Select a location to view capabilities
Supplier Network & Vetting Process
Our diverse network of manufacturing partners undergoes rigorous vetting to ensure exceptional quality, reliability, and value for your production needs.
Our Manufacturing Ecosystem
Third-Party Partners
Rigorously vetted contract manufacturers who meet ASTRON's exacting standards for quality, reliability, and performance. Each partner undergoes comprehensive evaluation before joining our network.
Key Benefits:
- Access to specialized capabilities
- Geographic diversity for supply chain resilience
- Competitive pricing through our aggregated network
- Full compliance with industry quality standards
Performance Metrics:
Invested Suppliers
Manufacturing facilities where ASTRON holds strategic equity positions, ensuring deeper integration, priority capacity allocation, and direct influence over quality processes and technology investments.
Key Benefits:
- Guaranteed capacity allocation during high demand
- Co-development of proprietary manufacturing processes
- Enhanced visibility into operations and scheduling
- Streamlined communication and collaboration channels
Performance Metrics:
ASTRON-Owned Facilities
Fully integrated, high-tech manufacturing sites representing our flagship capabilities. These facilities showcase our most advanced technologies and serve as centers of excellence for manufacturing innovation.
Key Benefits:
- Complete control over quality, scheduling, and capacity
- Most advanced machinery and manufacturing techniques
- Leading R&D capabilities and process innovation
- Highest level of IP protection and security protocols
Performance Metrics:
Our Vetting Process
AI-Powered Supplier Vetting
Our proprietary AI platform automates the supplier selection process, ensuring optimal matching based on precision, lead time, and cost requirements.
Process Steps:
Initial Assessment
AI algorithms analyze supplier capabilities, historical performance, and specializations
RFQ Management
Automated distribution of RFQs to pre-qualified suppliers based on project specifications
Performance Scoring
Real-time evaluation using our proprietary 126-point assessment framework
Continuous Monitoring
Ongoing tracking of delivery times, quality metrics, and customer satisfaction scores
AI-driven Supplier Selection Visualization
Global Supplier Network
Strategic Global Coverage
Our manufacturing network spans 4 continents, 18 countries, and over 200 qualified facilities, providing unmatched geographic diversity, redundancy, and localization options.
47
Third-Party Partners
12
Invested Suppliers
5
Owned Facilities
Manufacturing intelligence & industry innovation
The Strategic Advantage of Nearshoring in Modern Manufacturing
Exploring how North American manufacturers are leveraging nearshoring to reduce supply chain risks while maintaining quality control.
AI-Powered Quality Control Systems: The Future of Production
How machine learning algorithms are revolutionizing quality assurance in precision manufacturing environments.
Digital Twins in Manufacturing: From Design to Production
Implementing digital twin technology to create virtual replicas of physical assets for optimized production processes.
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Get a Detailed Engineering Quote
Upload your CAD file and our engineering team will perform a comprehensive analysis to deliver an accurate, optimized manufacturing quote for your large-scale production needs within 48-72 hours.
Thorough analysis – Get accurate quotes in 48-72 hours
Design optimization – AI-powered suggestions to reduce costs
Material recommendations – Smart suggestions based on requirements
Process selection – CNC machining or casting recommendation
"ASTRON's thorough engineering analysis transformed our sourcing process. We received an optimized quote within 48 hours and saved 22% on our large-scale manufacturing."
Sarah Chen, Procurement Director