Bruschi USA: Milwaukee Area - Zinc Die Casting

With more than 70 years of experience in zinc die casting Bruschi implemented a global development strategy in the last decade. 
For this reason in 2019 Bruschi embraced the opportunity to acquire Huf die casting facility in Milwaukee. 

Bruschi has been partner with Huf for some years now, supplying Huf with components for their mechanical and electronic locking systems and vehicle access and authorization systems for the automotive industry. 

With Bruschi the facility in Milwaukee will continue its current production for Huf Group and it will also be combined with projects brought from Italy: Bruschi is bringing to the US its vacuum technology, co-design service and innovative surface treatment all integrated into a vertical approach to die casting. 

The aim in Bruschi USA is to provide worldwide customers with the same all-in-one services and tailored solutions Bruschi has been offering for so many years from Europe. 

It is with this spirit that Bruschi welcomes the adventure of a firm breakthrough in its production capability in North America!

 

NA HUF

 

▪ Idea

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

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.

▪ Simulation

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.

▪ Rapid Prototyping

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.

▪ Tool Design

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.

▪ Tool Construction and Maintenance

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.

▪ Die Casting & Mass 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.

 

▪ Mechanical Operations

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

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 Chrome

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.

▪ Assembly

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.

References 

Every customer we had has helped us developing our method and enriching our know-how.
Our components are part of everyday life: electronics, automotive, electromechanical, building, furniture, lighting, small and major appliances. Being always well-aware that its products will be used frequently, all over the world, by millions of people, Bruschi understands that its client’s needs span down to those of final end-users: it is their satisfaction the ultimate key for success.

Our adaptability has made us capable of covering requests from many different sectors:

  • AUTOMOTIVE
  • ELECTRONICS
  • TEXTILE INDUSTRY
  • LIGHTING
  • DOORS AND WINDOWS
  • ELECTROMECHANICAL
  • APPLIANCES
  • COFFEE MACHINES

Our experience in zinc die casting is what gives us the ability to offer solutions fitting each request.  We take pride in our costumers and their trust in our company: their products become the best testimonial of our die-casted products’ value.

 

 

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