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Aluminium die casting specialist keeps a traditional product alive

26/09/2017 16:23:59
 
 
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ImagesClick Image for 300dpi jpg fileAluminium die casting specialist keeps a traditional product aliveAluminium die casting specialist keeps a traditional product aliveAluminium die casting specialist keeps a traditional product aliveAluminium die casting specialist keeps a traditional product alive

When British-based smoking pipe manufacturer Falcon Pipes was looking for a new supplier for their cast aluminium pipe stems, they needed a manufacturer capable of producing the intricate parts from a particularly challenging aluminium alloy. This search was concluded in North Wales after finding a specialist die casting company that could deliver the high quality products required.

Upholding a tradition

Invented in 1936 by Kenly Bugg and first sold in North America in 1940, the Falcon pipe design is unique and well-known amongst tobacco smokers to provide a smoother, cleaner smoke.

The system is based on the principle that causes rain to drop from a cloud when it is met by cool air. Mr Bugg selected aluminium for the stem because it is lightweight and, more importantly, for its ability to disperse heat quickly. The design cools the smoke as it travels along the stem and any condensation collects in the reservoir below the bowl, preventing from reaching the mouth of the smoker.

The bowl itself is screwed into the stem, allowing the style and appearance of the pipe to be changed. Many pipe smokers prefer to have a variety of different bowls for different tobaccos to prevent stronger flavours from overpowering more delicate blends.

Now a UK-owned manufacturing company, Falcon Pipes continues to manufacture the same design, representing modern technology and traditional craftsmanship in all its refinery. It is important therefore that the best materials are used for the stem and bowl and that they are manufactured to the highest standards.

Introducing Mark Aluminium Die Castings

Based in Colwyn Bay, North Wales, Mark Aluminium Die Castings (MADC) has been producing high quality, pressure die cast aluminium parts for decades. Used extensively in the automotive industry for water pump casings, these parts are often intricate and required to meet the high quality levels set by automotive manufacturers. With such extensive design and manufacturing experience, the expertise that MADC has is ideally suited for the manufacture of similarly intricate die cast parts.

The aluminium used for the pipe stem is an alloy known as LM5, which has been chosen for its corrosion resistance and its ability to maintain a highly polished surface. However, the challenge faced with casting this alloy is its poor flow properties compared to other commonly cast alloys and is therefore often avoided when complex designs are required. Knowing this, MADC successfully designed and manufactured suitable moulds, considering the best die design to achieve optimum material flow and finish quality.

David Lewis, European Head of Operations at MADC, comments: “We are very proud to be involved with such a traditional and prestigious company as Falcon Pipes, knowing they place their trust in us to uphold the highest quality standards. While this particular alloy and product finish challenged our processes, we considered the complex aspects of the mould design and arrived at a product which met the high level of quality expected by Falcon. Customers trust us knowing we have the experience and expertise to produce to their requirements, so while this application is challenging, we have proven MADC can manufacture products of this complexity.”

Photo Captions:

Photo 1: Invented in 1936 by Kenly Bugg and first sold in North America in 1940, the Falcon pipe design is unique and well-known amongst tobacco smokers.

Photo 2: Falcon Pipes were looking for a new supplier for their cast aluminium pipe stems, they needed a manufacturer capable of producing the intricate parts from a particularly challenging aluminium alloy.

Photo 3: Now a UK-owned manufacturing company, Falcon Pipes continues to manufacture the same design, representing modern technology and traditional craftsmanship in all its refinery.

Photo 4: The aluminium used for the pipe stem is an alloy known as LM5, which has been chosen for its corrosion resistance and its ability to maintain a highly polished surface.

About Mark Aluminium Die Casting

Mark Aluminium Die Casting offers a flexible small-to-large volume Aluminium die casting service. We provide design advice, tooling and specialist technical support. We differentiate ourselves by our service levels and responsiveness, we also maintain high quality standards and of course, finding ways to be extremely cost competitive. We can also test, pack and stock your items ready for immediate call-off delivery.

Cast aluminium parts have been manufactured at our site in Colwyn Bay, Wales for over 30 years. The company currently operates a modern furnace and a series of large high pressure aluminium die casting machines producing parts for automotive, electrical and electronics applications. In-house design, high-pressure aluminium die casting, engineering, manufacturing, assembly and testing, plus a large stock facility are all located on one site.

We employ a mixture of UK, EU and Chinese manufactured dies and moulds in order to meet a wide range of price, precision and volume demands.

For longer runs and super precision applications, the best quality tooling is always required, which we source locally. However in order to remain cost competitive and support companies that wish to re-shore their manufacturing base – in order to become more flexible in terms of volumes and reduce lead times and supply chain vulnerability – we also offer a manufacturing service based on a highly cost competitive production model.

Mark Aluminium Die Casting offers a full design, manufacture and test service for the OEM and replacement markets where volumes range from 1,000s to hundreds of 1,000s of parts. We also have a large engineering, assembly and packaging facility, logistics and a huge on-site stock capacity.

Editor Contact

DMA Europa Ltd. : Rebecca Hatch
Tel: +44 (0)1562 751436 Fax: +44 (0)1562 748315
Web: www.dmaeuropa.com
Email: rebecca@dmaeuropa.com

Company Contact

Mark Aluminium Die Casting : David Lewis
Tel: (0)1492 544201 Fax:
Web: www.madc.eu
Email: info@madc.eu

 
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