Assembly and Sub-Assembly Services -Complete Components from One Source

KastMfg's assembly capability extends single-source supply from machined castings to complete sub-assembled components -reducing supplier count, eliminating inter-supplier logistics, and providing one quality record for the complete component.

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Assembly Operations

Threaded Insert Installation

Aluminum die castings frequently use threaded inserts for stronger, more durable threads than the alloy can supply in tapped form.

• Helicoil (wire insert): M3-M20, screwed into pre-tapped hole. Thread strength equal to solid steel; removable for replacement.
• Keensert (solid insert): Interference-fit with locking tangs. Higher pull-out than Helicoil for high-cycle applications.
• Heat-set insert: Pressed with heat -common in magnesium applications.

KastMfg installs all insert types using torque-controlled tooling. Pull-out strength verification on first articles.

Bearing Press-Fitting

Bearings in aluminum housings require controlled interference fit and squareness. KastMfg uses hydraulic press stations with:

• Load-vs-displacement monitoring to verify complete seating
• Squareness fixtures: bearing face perpendicular to bore within 0.02 mm
• Post-press CMM verification of housing bore distortion

O-Ring and Seal Assembly

For hydraulic and pneumatic housings:

• O-ring pre-lubrication with compatible lubricant (silicone or petroleum per fluid type)
• Visual and dimensional verification of correct size and cross-section
• Functional check: O-ring seated correctly, no twist or pinching

Fastener Assembly

• Screw/bolt torquing with calibrated power tools (±5% torque accuracy)
• Stud installation (press-in or thread-locking compound)
• Loctite application per vibration-resistance specification

Sub-Component Integration

• Shaft and gear insertion into housings
• Valve spool and spring installation
• Electrical connector mounting
• Gasket fitting and housing closure

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Quality Control for Assembly

• Work instructions: Step-by-step with torque values, orientation checks, and inspection points
• Poka-yoke: Fixtures preventing incorrect assembly (wrong insert, missing O-ring, wrong orientation)
• In-process inspection: Dimensional check after each critical step; functional test on assembled units
• Traceability: Assembly records link to casting batch, component lots, and operator

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Packaging for Assembled Components

• Individual foam-lined trays (prevents bearing surface damage)
• Protective caps on threaded features and sealing faces
• Desiccant packs for bearing/corrosion-sensitive surfaces
• Customer-specific labeling and kitting

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Assembly inquiry: yaoqingpu1983@gmail.com | +86 138 1403 4409 | No.6, Rungu Road, Nanjing, China