Posted by Stacy Hill on | Comments Off on From Minnesota to the Moon
It’s officially February which means NASA’s Artemis II mission marks a historic return of humans to deep-space exploration, sending astronauts on a journey around the Moon for the first time since the Apollo era. Artemis is NASA’s long-term program designed not just to revisit the Moon, but to establish a sustained human presence there, laying the groundwork for future missions to Mars. Building on the success of Artemis I, which proved the systems needed for deep-space travel, Artemis II represents a major step forward by carrying a crew and pushing human exploration farther than it has gone in more than 50 years.
At Midwest Metals, this mission feels personal. We’ll be watching with anticipation, not just for the launch, but when the massive Crawler-Transporter moves Artemis into place at Kennedy Space Center. We were honored to develop 17 parts for that transporter right here in Winona, MN. Working with our client, Innovative Hydraulics, Midwest Metals cast eight identical steel cylinders, each six feet long and weighing 1,100 pounds. These cylinders play a critical role in supporting the transporter responsible for moving NASA’s most powerful rockets. Seeing our craftsmanship contribute to a mission of this scale is a proud reminder that world-changing exploration starts with precision work at home.
Posted by Stacy Hill on | Comments Off on Midwest Metal Products Upgrades with New Blanchard Grinder
Midwest Metal Products has expanded production with the addition of a second Rotary Surface Grinder. Manufactured by Blanchard Machine Company, https://www.bourn-koch.com/, This machine complements MMP’s current Rotary Surface Grinder and will enhance production speed, precision, and overall efficiency by doubling current capacity with this upgraded piece of equipment.
What is the Blacher Grinder?
The Rotary Surface Blachard Grinder is a high-performance precision tool known for its ability to provide smooth, precise finishes on flat metal surfaces. Its combination of speed, reliability, and advanced performance makes it ideal for both small-batch and high-volume production runs, helping manufacturers achieve greater efficiency and product consistency.
With the addition of this new equipment, MMP has expanded its production capacity and strengthened its ability to meet growing customer demand. Operating two grinders simultaneously will allow the company to process more orders at once, reduce lead times, and deliver projects faster
Posted by Stacy Hill on | Comments Off on Midwest Metal Products Teams Up with Virginia Tech for the 2025 Cast in Steel Competition
The 2025 Cast in Steel Competition is in full swing, and Midwest Metal Products is thrilled to be partnering with Virginia Tech’s College of Material Science and Engineering to bring history to life. This year’s challenge? Crafting a model of George Washington’s iconic sword.
As a leader in metal manufacturing, we were honored to play a crucial role in this prestigious competition. Virginia Tech’s team, the Iron Maidens, had a great start but needed expert support in key areas. That’s where we came in.
Our Role in the Project
Computer Modeling & Simulation: We provided the Virginia Tech team with a CAD model of the sword, which they could use to run solidification simulation trials on to determine the best approach to making a sound casting
Casting Guidance: With our extensive experience in metallurgy and casting, we provided expert insights to enhance the design for manufacturing.
Material Supply: We supplied the necessary materials to ensure the project’s success.
Blanchard Grinding: Using our Blanchard grinder, we were able to quickly remove material to make the sword blanks the desired thickness and straightness.
This isn’t our first time working alongside Virginia Tech. Back in 2020, we collaborated with their team for the Cast in Steel competition when they crafted a Bowie Knife that won the prize for “Best Performance.” We’re thrilled to build on our past success and push the boundaries of what’s possible together.
Meet the Iron Maidens’ Team
The Virginia Tech team is made up of dedicated and talented individuals who poured their hearts into this project:
Alan Driusctiz – Faculty Advisor
Ashley Lacy
Mitchell McClure
Bethany Gansemer
Ashton O’Rourke
Nikki Powell
A Student’s Perspective: Ashley’s Experience
For Ashley Lacy, one of the students on the project, the most rewarding part was seeing the sword come together at the last moment:
“We created many individual components separately, and since most of the work came together at the last minute, seeing everything finally take shape was incredible. It was a beautiful moment to see that our hard work had paid off in the end.”
Ashley also highlighted the crucial role Midwest Metal Products played in their success:
“Midwest Metal Products was an invaluable partner in this project! As Materials Science and Engineering majors at VT, we aren’t formally trained in CAD, but we needed CAD files for the simulation software we used (MAGMA, which simulates metal flow in casting). David (Michalski, MMP Foundry Engineer) was incredibly generous in producing three different CAD models for us—one with a channel, one without, and one with a tapered design. Having those files allowed me to develop different gating systems in MAGMA using various patterns.”
“Throughout the project, Jeanne (Wagner, MMP Technical Director) consistently checked in, offering assistance and meeting with us multiple times to discuss the next steps. They also provided charge materials for our H13 steel and helped with Blanchard grinding three different swords. Midwest Metal Products’ support was crucial to our success. We truly couldn’t have completed this project without them.”
“This project was an incredible opportunity, and we were so fortunate to have such a supportive industry partner. I’ll be graduating in May, but I hope future VT teams have the chance to collaborate again!”
Competition Details
The competition will culminate in a series of rigorous tests from April 9-11, with the awards ceremony set for April 12 in Atlanta, Georgia. Teams from across the nation will showcase their craftsmanship, precision, and engineering expertise as they compete to create the best steel recreation of George Washington’s sword.
We’re honored to be part of this exciting journey and couldn’t be prouder of the Iron Maidens. We wish them the best of luck in the competition and can’t wait to see the final product in action! Stay tuned for updates!
Posted by Stacy Hill on | Comments Off on Midwest Metal Products Partners with Minnesota SE Tech College
At Midwest Metal Products, we believe in investing in the future of manufacturing by providing real-world training opportunities for the next generation of artisans. That’s why we recently partnered with Minnesota Southeast Technical College’s welding program on a manufacturing project aimed at enhancing students’ hands-on experience.
Over the course of two weeks, 10 students from Minnesota SE Tech College had the opportunity to engage in production welding. This program not only allowed them to apply their classroom knowledge in a real-world setting but also gave them exposure to the high standards and precision required in a manufacturing environment.
To ensure the students had the best experience possible, one of our own experienced welders stepped in, providing guidance, oversight, and quality inspections throughout the process. MMP also supplied all necessary components, including castings, weld wire, and more to ensure that students had access to the same materials used in professional production welding. The results of this partnership were outstanding as the students performed exceptionally well, demonstrating both skill and eagerness to learn. Their contributions helped us complete valuable work while they gained practical experience under the supervision of our team. This collaboration proved to be mutually beneficial, as it not only provided students with invaluable learning experience but also allowed us to make a meaningful impact on the community.
Looking ahead, Midwest Metal Products is committed to continuing our support of Minnesota SE Tech College’s welding program. To strengthen this relationship, we are reimbursing the school with donations to their welding department, ensuring that future students continue to receive high-quality equipment.
At MMP, we take pride in investing in the next generation of welders. This successful partnership is a testament to the power of collaboration between industry and education, and we look forward to more opportunities to support workforce development in our community.
Posted by Stacy Hill on | Comments Off on Sustainable Innovation: MMP’s Solar Powered Success
Midwest Metal Products has distinguished itself within the metal casting industry through innovative technologies and a commitment to sustainability. Among the notable achievements, MMP is recognized as the first commercial foundry in North America fully powered by solar energy, including its energy-intensive melting operations.
Since its establishment in the 1950s, the MMP site has undergone significant transformation. Initially operating as a green-sand gray iron foundry, it expanded in the 1980s to integrate heat-treating capabilities. By 1991, the foundry introduced air-set molding and began producing both steel and iron. Today, MMP employs induction melting technology with the production of castings capable of reaching up to 1,800 lbs. for irons and 1,100 lbs. for steels.
Solar-Powered Operations
A distinguishing feature of MMP is our commitment to renewable energy. In 2015, the foundry joined the Minnesota Community Solar Garden (MCSG) initiative, a cooperative program that facilitates the installation of dense photovoltaic (PV) solar panel arrays. These arrays supply power to the regional energy grid, with participants receiving credits for the electricity generated. By mid-2016, MMP had subscribed to four solar gardens, covering over 100% of its energy requirements based on historical consumption data.
Each solar garden can generate 1 MW of power, requiring approximately 2.5 acres of land. MMP’s gardens, operated by BHE Renewables, became operational in February 2018. The solar energy initiative has reduced the foundry’s energy costs, with projected annual savings of about 1 months worth of electrical cost per year. The foundry has even sold excess power back to the grid, though this is expected to diminish as production scales up.
Minnesota’s MCSG initiative has positioned the state as a leader in renewable energy adoption, with 58 solar garden projects completed as of December 2017 and more in development. These gardens are designed to supplement traditional power sources and align with Minnesota’s mandate for electrical providers to derive at least 1.5% of their supply from solar energy.
MMP’s participation in this program reflects both an environmentally responsible business strategy and a forward-thinking approach to sustainable manufacturing. By leveraging renewable energy, the foundry aligns its operations with broader environmental goals while maintaining operational efficiency.
In conclusion, Midwest Metal Products exemplifies the integration of advanced technology and sustainability within the metal casting industry. Through innovative practices, coupled with a commitment to renewable energy, MMP positions itself as a model for other foundries seeking to enhance their capabilities while minimizing their environmental impact.
Posted by Stacy Hill on | Comments Off on Midwest Metal Products at The Steel Founders Society of America Technical and Operating Conference 2024
The Steel Founders Society of America (SFSA) hosted its much-anticipated Technical and Operating Conference from December 11-14, 2024, in downtown Chicago. Supported by steel foundry members that make up the Society, the T&O Conference is one of the premier steel casting events in the world. This annual event brought together industry leaders, innovators, and technical experts from member foundries across the Americas and Europe to share insights, advancements, and strategies shaping the future of the foundry sector.
Now in its 78th year, the T&O Conference continues a proud legacy of addressing the technical and operating topics of today that provide value to the industry for many years to come. This year’s workshop featured topics such as Artificial Intelligence, robotics, and the Craftsmen with Character initiative. There was a more extensive range of discussions, including melting, foundry engineering, molding, finishing, EHS, quality, and technical and featured research.
Midwest Metal Products Contributes
Among the many contributors, Midwest Metal Products stood out by presenting four impactful technical papers to reinforce our position as a leader in foundry innovation. MMP’s President, Joe Plunger, along with Technical Director, Jeanne Wagner, led our presentations by delivering insights on pivotal topics:
Economic Forecasting: An analysis that provided participants with valuable tools and strategies to navigate economic challenges and capitalize on emerging opportunities in the foundry industry.
Advancements in Knock-Off: Highlighting improvements in removing risers and gating systems, this presentation showcased a cost-effective method to enhance productivity and reduce waste in casting finishing.
Pressurized Risers: This paper explored advancements in riser applications, specifically with the intention to improve casting soundness.
SFSA Market Forecast: This paper provided a comprehensive overview of market trends, enabling foundries to align their strategies with future demands and industry shifts.
A Platform for Global Collaboration
The conference underscored SFSA’s dedication to fostering a global community of innovation and excellence in the foundry industry. Attendees hailed from different parts of the world, bringing diverse perspectives and experiences. The event provided an unparalleled platform for networking, problem-solving, and envisioning the future of foundry technology and operations.
With the bar set high in 2024, Midwest Metal Products is already looking forward to the next gathering where the foundry community will once again come together to shape the industry’s future.
Posted by Stacy Hill on | Comments Off on 2024 “10 Days of Giving” Drive
In 2024, the 36th annual “10 Days of Giving” drive in Winona, led by Merchants Bank, continued its tradition of supporting the food shelf at Winona Volunteer Services. This year’s effort contributed to the impressive milestone of over 4 million pounds of food collected to date.
Midwest Metal Products proudly raised $2,990.97, surpassing our 2023 total by over $1,000! This incredible contribution was made possible by the generosity of our employees. Thanks to this, MMP made a significant impact on families in need within our community.
Monetary and non-perishable food donations from individuals, local businesses, and organizations poured in throughout the campaign. Donations were accepted at any Winona Bank lobby, participating locations, and during special events, showcasing the collective spirit of our community.
A heartfelt thank you to everyone who contributed to making the 2024 drive a success. Together, we are making a difference—let’s carry this momentum forward into future years!
Posted by Stacy Hill on | Comments Off on About the MMP Culture
At Midwest Metal Products there is no simple answer to the question “What do we do?” From a business standpoint, we’re a foundry that produces castings. While this is accurate, it only scratches the surface of what MMP is all about. We offer much more than raw castings; we collaborate closely with our suppliers to provide finish-machined, painted, and sometimes assembled parts. Our collective expertise allows us to tackle a wide range of challenges.
Understanding who we are at MMP is crucial to defining our culture and setting realistic goals for our future. Our culture shapes the way we interact with each other, our clients, suppliers, and the community. As part of our strategic planning, we identified six key characteristics that define our culture and what they look like in action at MMP:
Respectful:
We value each other’s time and talents, fostering empathy, honesty, integrity, and transparency. Our guiding principle is simple: “Treat others how they want to be treated.”
All in This Together:
We collaborate with suppliers, clients, and teammates to achieve and exceed our goals. No one person or task is more important than the team. Together, we are stronger.
Learn & Be Curious:
We are committed to continuous improvement and innovation. We embrace questions, experiment with new ideas, and learn from both our mistakes and successes. After all, knowledge is power.
Open-Minded:
We welcome feedback and engage in constructive discussions to explore diverse perspectives. By valuing individual differences, we broaden our vision and find the best solutions.
Good People with a Small-Town Atmosphere:
We cultivate a warm and friendly environment for employees, clients, and suppliers alike. Our reliability and trustworthiness create a community where “Good people bring out the good in others.”
Lead by Example:
We recognize our strengths and contributions, striving to do our best every day. Our actions reflect our commitment to our shared values—“Be real.”
At MMP, our culture is the foundation of our success and the key to our future.
Posted by Stacy Hill on | Comments Off on 3 Things to Consider When Choosing a Metal Casting Foundry
To help you succeed with any type of metal casting project, it’s important to select a metal casting foundry with the capabilities you need. The ideal foundry produces high-quality, cost-effective components with fast turnarounds. Read on to learn how to choose the best foundry based on its location, expertise, resources, and capabilities.
What Is a Metal Casting Foundry?
Metal casting foundries use various casting techniques to produce metal components. All of these techniques involve melting the metal and dropping it into a unique mold to form the desired part. Depending on the required volume, material characteristics, and complexity of the part, a foundry may choose between the following common casting processes:
Sand Casting: This traditional process uses sand molds to form the desired part shape.
Die Casting: Foundries inject molten metal into a die, accurately forming complex components under high pressures.
Investment Casting: This process produces high-precision, intricate parts with tight tolerances and good surface finishes.
Gravity Casting: Gravity casting involves pouring melted metal into a shaped mold without exerting pressure.
Benefits of a Metal Casting Foundry
With the help of the right metal casting foundry behind your casting project, you can benefit from:
Adaptability: Whether you need to fabricate small, decorative metal pieces or complex, structural components, foundry casting makes it easy to do so using a range of metals, including steel, iron, brass, aluminum, and cast iron.
Efficiency: The right metal foundry can produce castings with consistent efficiency to provide fast turnarounds for high-volume projects.
Recyclability: Metal castings can be recycled, melted down to create new components. Thus, metal casting is a sustainable, circular process that can make use of scrap metal.
Processes Metals With High Melting Points: Certain metals like titanium and steel offer superior durability but can be difficult to fabricate with other methods because of their high melting points. However, metal casting is suitable for these types of alloys.
Quality and Precision: When you choose the best metal foundry for your needs, you’ll get quality parts with the level of precision your project requires. This eliminates the need for rework and contributes to a high-quality end product.
Increased Total Project Value: Metal foundries can combine multiple separate components into a single casting with uniform properties throughout, strengthening the reliability of the overall assembly.
Cost-Effectiveness: The lower cost of fabricating parts using casting processes translates to cost savings for the end customer.
3 Things to Consider When Choosing a Metal Casting Foundry
Here are the main factors to look for in the ideal metal casting foundry.
1. Industry Experience
Choose a metal foundry with specialized expertise in your industry or application. They should be able to understand the unique challenges of your project and select the right casting process to complete it. Also check that they have strict quality control measures in place to produce consistently superior-quality components.
2. Capabilities and Capacity
Determine whether your chosen metal foundry has the capacity to handle your project, especially if you’re working with high volumes or tight deadlines. Review each prospective foundry’s equipment and resources to help determine if they have the capabilities to meet your needs. Material availability is another key factor here, as the foundry should have ample metal alloys to produce your parts.
3. Location and Logistics
Consider the metal casting foundry’s location, as closer proximity to your facility can help you save time and money on transportation. Your casting provider should have efficient logistics management for storage, inventory, and shipping. The ideal foundry will also be able to work closely with you and maintain clear, consistent communications.
Reach Out to Explore Midwest Metal Products’ Capabilities
For the best metal casting solutions, turn to the experts at Midwest Metal Products. Our skilled metal foundry employees and fully equipped facility can provide you with a customized and durable casting solution based on your unique requirements. Lean on our industry expertise, extensive technical capabilities, and logistics solutions to get your project done right the first time, every time.
For more information about our processes and capabilities, contact us today. You may also request a quote to get started with a custom solution.
Posted by Stacy Hill on | Comments Off on Top Three Metal Materials Used in Casting: Full Guide
From structural components and aerospace parts to consumer goods and decorative items, versatile metal casting processes create complex shapes from molten metal through high-volume production. As casting is compatible with a broad spectrum of material options, you can select the one that best fits your product requirements, part design, application, and budget. Learn more about the techniques and common materials involved in casting to help you choose a metal with confidence.
About Casting Metal
Metal casting encompasses several controlled processes of pouring molten metal into a hollow mold so that, as it cools, the material hardens into a preconfigured shape.
Types of Metal Casting Processes
Examples of metal casting techniques include:
Sand casting. Utilizing a sand mold is the most common metal casting technique.
Die casting. With a metal mold, or die, foundries can generate complex parts with precision.
Investment casting. Investment or lost wax casting employs a refractory material-coated wax pattern as a mold.
Centrifugal casting. By pouring metal into a mold as it turns, the motion causes material flow in an outward direction. The metal solidifies against the mold’s walls as it cools.
Continuous casting. Also with a moving mold, this casting technique uses the ongoing motion to create parts in lengthy, continuous sections.
Advantages of Casting
Each casting method has its own benefits and ideal uses, but they share the following key advantages:
Complex shapes. Casting processes can create geometrically complex and intricately detailed parts that other manufacturing techniques cannot.
Large order volumes. The casting method is perfect for high-volume production of uniform components.
Cost-effectiveness. A side benefit of being able to produce large quantities is that casting can be an economical manufacturing choice, lowering per-part costs.
Material options. With versatile metal casting, you can choose from an array of different materials to suit your needs.
Which Type of Metal Is Used in the Casting Process?
To determine which type of casting material is right for you, select a material that will deliver the required properties for your product. For example, evaluate a material for its strength, weight, resistance capabilities, price, and workability. Ferrous metals like steel and iron can lend your product impressive strength and durability, while non-ferrous varieties such as aluminum and zinc tend to offer good machinability.
Before we get into the top three types, we’ll first discuss other common metal casting materials:
Stainless steel. This steel variety is strong, inert, and hygienic, making it ideal for anything from structural components to food processing and healthcare equipment.
Abrasion resistant cast iron or chrome and nickel hard irons. These iron varieties are made with higher concentrations of the alloy elements to enhance wear characteristics, used in wear liners, pumps, piping, and other applications that need great wear properties.
Brass. Malleable brass offers good machinability. Its corrosion resistance makes it appropriate for plumbing fixtures, while its pleasing aesthetics lend it to applications ranging from doorknobs to musical instruments.
Bronze. This copper-tin alloy is a strong metal variety, resisting general wear and corrosion. It has both functional and aesthetic uses, from gears and bearings to artistic sculptures.
Zinc. Compatible with the die casting process for its low melting point, zinc is good for hardware, vehicle parts, and even children’s toys.
Top Three Metal Materials Used in Casting
Which metals, then, are your top metal casting options?
1. Aluminum
Among the lightest and most abundant of metals, aluminum has a great strength-to-weight ratio and — given its superior machinability — can help reduce your production costs. Being lightweight and corrosion-resistant makes it highly popular for aircraft and vehicle parts in which weight reduction and durable construction are of great importance. Aluminum is available in many different alloys, each one unique and possessing its own benefits, so it’s a versatile choice with both indoor and outdoor applications.
2. Steel
Steel is primarily prized for its strength. While it can also be used in vehicle parts, steel components are reliably durable enough to handle structural and industrial equipment projects, as well. Similarly to aluminum, steel is flexible in its applications because of its numerous available alloys, such as stainless, carbon, and alloy steel. However, when discussing the material itself rather than its machining process, steel is a more affordable material option than aluminum or metals like copper.
3. Cast Iron
One of its primary benefits where metal casting is concerned is that cast iron has good fluidity when it’s in its molten state, facilitating part production in complex shapes. Cast iron parts can handle applications that will expose them to friction as the metal offers exceptional resistance to wear. This tough material is also thermally conductive, allowing parts like engine blocks to conduct heat. As for pricing, cast iron typically beats out both aluminum and steel, making it another economical choice.
Quality Castings for All Metal Types by Midwest Metal
At Midwest Metal Products (MMP), our foundry provides quality engineering, casting, heat-treating, and finishing services. We’re dedicated to adding value for our customers, enhancing product reliability, and reducing part count. Contact us to learn about our casting services and which metal is right for your project, or request a quote today.
