Manufacturing

At Amalga Composites, we have 2 manufacturing facilities with a combined square footage in excess of 115,000 sf. These facilities house 3, 200×40 foot overhead crane bays, 6 production lines, 3 coating/painting areas, shipping docks, and complete machining capabilities to provide customized, high volume output for both domestic and international orders. 

We have a 120×20 foot temperature and humidity controlled molding area, designed specifically for composite structures in order to efficiently cure your product to the design specifications, and ensure consistent and reliable quality.

Amalga specializes in the following manufacturing techniques:

Filament winding:

The highest quality fiberglass and carbon filaments are precisely wound at angles calculated to provide optimum stiffness and tensile strength for each application. The tubing is then machine finished to final engineering tolerances.

 

Amalga Composites is one of the largest filament-winding operations in the United States.

Compression molding:

Compression-molded parts offer a strong, lightweight alternative to die-cast, stamped or other formed metal parts due to their superior:

-Corrosion Resistance       –Chemical Resistance

-Heat Resistance                       –Fire Retardation

-Weight Profile                     –Weather Resistance

-Colorfastness                                            –Strength

-Microwave Transparency                                        

  •  

We specialize in robotic winding and machining of all composites:

Reinforcements

  • Carbon
  • Fiberglass
  • Aramids
  • E-glass
  • S-glass
  • Kevlar 
  • Broad goods

Matrices

  • Epoxy 
  • Vinyl 
  • Ester

We are capable of manufacturing in all composite mediums

Winding Capability :

Amalga Composites has capabilities to produce tubing from ½ to 44 inch diameters and lengths to 30 feet. We’re able to accomplish this because we have 14 Winding Machines, including: 

  • 2        4 axis computerized machines
  • 6        2 axis computerized machines with off line computer programming capabilities
  • 2         7 foot computer control 3 spindle machines
  • 1         15 foot computer control 2 spindle machine
  • 1        15 foot computer control 3 spindle machine 
  • 1       36 foot computer control 4 axis winder 
  • 1        4 meter 4 spindle winding machine

Gel Coating Machine:

We use the Magnum Venus automated gel coat application machine to produce Black Amalgon cylinder tubing

Resin transfer molding:

Resin transfer molded parts offer a strong, lightweight alternative to die-cast, stamped or other formed metal parts and are the preferred alternative to open molded fiberglass processes. Fiber Reinforced Plastic molded components provide an excellent alternative to metal for: 

  • Part Consolidation
  • Corrosion Resistance
  • Chemical Resistance
  • Heat Resistance
  • Fire Retardant
  • Weight Reduction
  • Weather Resistance
  • Colorfastness
  • Strength
  • Microwave Transparency

 

Amalga’s doctoral-level engineering expertise provides quick and detailed assistance in getting your ideas into production quicker than metal technology.

 

We use state of the art processes and equipment, including: 

  • Magnum Venus automated epoxy resin transfer pumping system for Light Resin Transfer Molding (LRTM) 
  • Closed Contact Bag Molding (CCBM), and Vacuum Assisted Resin Transfer Molding (VARTM)
  • Cannon automated polyurethane foam dispensing system 
  • Sterling Hot-Water Mold heater 

Compression Molding:

We have everything needed to fulfill custom orders, large or small, including: 

  • 1 Verson 150 ton compression press
  • 1 Wabash 30 ton compression press
  • 1 Sterlco 2 zone oil heater
  • Steel rule clicker die

Compression Molding Processes

 Bulk MoldingSheet MoldingThick MoldingSMC Random FiberSMC-Chop/ContinuousPreform
Bosses & RibsYesYesYesYesNoNo
Cosmetic AppearanceGoodGoodGoodFair Fair Fair
Type of PartCastingStampingCast & StampingCastingCastingStamping
Size of PartSmallLargeMedium LargeLargeLarge
Tensile Strength (psi)5,00012,00010,00023,00055,00014,000
Flexural Strength (psi)15,00026,00022,00037,00085,00028,000
Specific Gravity1.901.752.001.851.801.20

Process Comparison to Steel

 Sheet Molded CompoundInjection Molded ThermoplasticAluminum
Part ConsolidationExcellentExcellentFair
Comparable Mass75%70%75%
Corrosion ResistanceBestBetterGood
Impact ResistanceBestBetterPoor
Tooling Cost40%60%100%
Stiffness6%2%30%
Thermal Expansion100-130%600-1000%170-200%

The properties listed do not constitute any warranty or guarantee of values. These properties are for material selection purposes only. For applications requiring guaranteed values, independent verification should be conducted.

Curing Equipment :

We have 10 ovens, all with 24 hour temperature controls and read-out devices with temperature indicators for Quality Assurance monitoring. These include: 

  • 1        2-stage continuous conveyor rotating oven 
  • 2        Rotating ovens 
  • 6        Walk-in cabinet ovens with varying capacities 
  • 1        Continuous conveying oven

Finishing Operation Capabilities :

At Amalga, we have complete facilities to grind, cut, and machine to exact specifications. This includes state of the art custom painting, and straightening presses to straighten mandrels and steel tubing.

Machining

Critical Production Details:

The best results are achieved using Forstner drill bits designed for composites

  • Drill bits with specific helix angles, wide-polished flutes and point angle for fiberglass-reinforced thermosets limits chip packing and overheating
  • Helix angles of 10 to 50 degrees, clearance of 9 to 20 degrees and point angles of 60 to 120 degrees are required
  • Vary drill speed with the size and depth of hole
  • Carbide and diamond-tipped tools will produce a smoother finish and are more responsive when operating at higher speeds and slower feeds
  • A bit that is approximately .002″ oversize is recommended
  • Support the backside of laminate with wood or plastic to prevent delamination and splintering.

 

We can ensure that by choosing to work with us, your composites will be correctly and expertly made. Amalga has years of experience working with composites, so we know how to best deal with them!

Assembly

We have the capability to perform assembly services depending on the project. Call us to see whether our assembly services are right for you.

Testing Equipment
We are constantly testing our products and developing new technology and techniques to meet your needs. Our current testing equipment includes: 
  • Differential scanning calorimeter
  • Meg-ohm resistance module 
  • Hydrostatic burst strength and proof test module 
  • Granite Inspection Tables 
  • Vibration Analyzer
  • Muffle furnace and analytical balance 
  • Customized measuring equipment 
  • Pressure Cycling Test Stand 
  • Dynamic Balancer
  • Tension/Compression Load Frame 
Quality Assurance
We’re not in the business of losing customers, and since 1966 we have built our business on fulfilling orders on-time, on-budget, and with excellence. Our quality control system provides repeatability and traceability on all composite components. Amalga Composites, Inc. was initially certified to the ISO 9001/2008 Quality Standard in 2010 and we have re-certified to the ISO 9001/2015 Quality Standard in 2017. Our ANAB certification number is: 2010-010.