Bruschi USA: Milwaukee Area - Zinc Die Casting

Ideas are the core of our business: many companies rely on Bruschi not only for the manufacturing of components, but also to require brand new design and projects.

In Bruschi R&D department, every idea is combined with our know-how to create the most functional products for our customers.

Co-design is a collaboration between client and supplier, and it is fundamental to optimize a product and  adapt it to the process of die casting.

To design both the product and the mold, our engineers use a 3D CAD software with integrated Finite Elements Method simulation software: these studies help reducing the gap between designs and production, optimizing the whole process.

Die casting simulation helps designers to foresee precisely all material reactions inside the mold cavity, through a thermo-fluid dynamic analysis.

In our engineering department we use MAGMASoft and other professional software to run VAVE analysis. By using this kind of software, it is possible to identify and prevent possible defects, optimizing the filling process to obtain the best result.

The term Rapid Prototyping identifies a group of techniques used to create a model of a physical part or assembly.

In Bruschi we make our prototypes using soft tool, in order to create a model that has the same mechanical and physical qualities of the final die casted piece in a reduced lead-time. Rapid prototyping enables realistic trials and testing before the actual start of production.

Bruschi Engineering department designs molds and tools, in addition to developing special automation projects based on our clients’ requests.

We design every tool needed in the production process: from the design of molds to peripheral devices, such as trimming tools, deburring machines, cooling systems, clamping robots, but also automations for machining and assembly.

In our Tool Shop, molds and all the complex periferical machines previously designed are built and tested, before becoming fully functional alongside mass production.

In our productive plant we can also count on integrated maintenance department that grants the continuity and steadiness of die casting production.

Our mass production is based on hot chamber die casting and vacuum die casting. Vacuum die casting is a technique that grants a stable, structurally flawless casting: the vacuum valve reduces air trappings, and therefore porosity in the diecast.

We melt over 4.000 tons of zinc every year and turn them into finished components.

Every component produced in Bruschi is refined and delivered to our customers with no need of further machining.

This is possible thanks to mechanical operations such as threading, drilling, assembly and reaming. Some of these operation are completely automatized, thus granting high precision and faster results.

Finishing techniques are mechanical processes aimed at changing a product's surface. They are usually necessary to prepare products for a galvanic, aesthetic or protective treatment, but they can also be the final stage of a component production.

In Bruschi we process components using vibration, sandblasting or polishing, granting smooth edges or shimmering components.

Painting and chroming are used to determine the final aesthetics of products, in addition to giving protection from oxidation and other external agents.

Bruschi provides products complete of surface coating, offering galvanic treatments, like chromium plating, and liquid or powder painting.

In Bruschi, we can cover requests for complex pieces that need to be combined together or with other components: the operations are carried out by machines for automatic assembly.

This allows us to provide our customers with pre-assembled components, ready to be integrated in the final structure.