Article Summary
We Invested in Casting to Provide The Highest Quality Products
Brandon Industries uses aluminum casting, primarily die casting, along with sand casting and gravity casting with permanent molds, to manufacture light poles, decorative signage, and mailboxes that hold up in outdoor, urban environments.
The lighting industry faces many challenges, which is why we put a lot of thought into our products. For example, when it comes to light poles, casting plays an important role in ensuring the best-quality products. As a leading provider of lighting solutions, we understand the value of aluminum casting. We are going to talk about the advantages of casting and how we have utilized it to the fullest to provide the highest-quality products for our clients everywhere.
The Properties of Casting
Die casting is the way forward for manufacturing and designing pole bases. Across the lighting industry, aluminum accounts for more than 80% of die-cast parts. It is not without reason that aluminum is the preferred material. Aluminum casting might not be the right choice for every project, but for most, it is highly preferred.
To begin with, aluminum is lightweight, ensuring the casting is made without added weight. At the same time, aluminum is resilient enough to handle a wide range of temperatures, making it a good choice for any temperature. Plus, properties such as good electrical and thermal conductivity, recyclability, and non-magnetic nature make aluminum a great fit for manufacturing poles and bases.
These properties are put to work across our full Complete Light Pole Solutions line, including Anchor Base Poles, where a cast aluminum base must withstand real wind loads for decades.
Casting Methods, Sand Casting, Gravity Casting & Die Casting
Not every cast aluminum part is made the same way. Brandon Industries chooses among three main casting methods depending on the part’s shape, finish requirements, and production volume.
Sand Casting
Sand casting uses a mold packed with sand around a pattern of the finished part. It is well-suited to lower production volumes and larger or more intricate shapes, since a new sand mold is formed for each casting.
Gravity Casting with Permanent Molds
Gravity casting pours molten aluminum into a reusable, typically metal, mold using gravity alone rather than injected pressure. The permanent mold can be used repeatedly, which gives a more consistent finish than sand casting at moderate production volumes.
Die Casting
Die casting forces molten aluminum into a steel die under high pressure. This produces the smooth surfaces, tight tolerances, and reduced machining described below, and is the method best suited to higher production volumes and finely detailed components such as pole bases and finials.
Casting Methods at a Glance
| Casting Method | Mold Type | Force used to fill the mold | Best for | Typical finish |
|---|---|---|---|---|
| Sand Casting | New sand mold per casting | Gravity, poured into loose sand | Lower volumes, larger or more intricate shapes | Rougher, more machining is often needed |
| Gravity Casting | Reusable permanent mold, typically metal | Gravity, poured into a fixed mold | Moderate volumes, consistent finish | Smoother than sand casting |
| Die Casting | Reusable steel die | High-pressure injection | Higher volumes, fine detail, smooth surfaces | Smoothest, minimal secondary machining |
The Benefits of Aluminum Casting
Whether it’s sign poles or finials, we invest considerably in aluminum casting and have derived several advantages from it. Some of them are as follows:
No Extra Weight
Increased weight is a concern we constantly strive to address when manufacturing lighting or mailbox fitments. With aluminum casting, the absence of the extra weight is the biggest advantage.
Resistant to Heat & Corrosion
Aluminum is a very durable material. As such, maintaining the stable temperature is not an issue at all. No matter how hot the temperature or how difficult the conditions, aluminum will never disappoint. Aluminum has a strong affinity for oxygen and forms a film of aluminum oxide on its surface, which prevents corrosion. In most environmental conditions, the rate of aluminum corrosion decreases with time.
Versatility
This metal is highly versatile, which is yet another reason aluminum casting is so necessary, especially for mailbox poles. In fact, the material works perfectly well whether you want extra-thin walls or a beautiful finish. It is highly ductile. With its low melting point and density, aluminum can be molded into any product near the end of the design cycle.
This same versatility carries over into our Mail & Parcel line, including Cluster Box Units & Parcel Lockers and Curbside Mailboxes.
Reduced Machining
Machining, as we all know, is an expensive operation that increases the overall costs. With aluminum casting, the amount of machining is drastically reduced. Aluminum offers a smooth finish. The surfaces can, in particular, be made truly flat and are often free of taper or draft. When secondary machining is reduced, the end product improves significantly in quality.
Once a part is cast, it still needs a finish that can withstand outdoor conditions. See how we handle that step in Why Powder Coat Paint Is Far Superior, or check our Product Finishes guide for available options.
How We Work
At Brandon Industries, we have been focusing on casting and ensuring that all castings are made from cast aluminum. We have been the leading provider of streetscape solutions for more than two and a half decades. We stand out in the industry by virtue of the following that we offer for our clients:
Competitive Pricing
The best price is indeed the most competitive in the market. We offer our products at highly affordable rates, without compromising on the quality.
Fast Lead Times
We understand that to thrive in this highly competitive industry, you need to deliver products to your customers quickly. We offer the best possible lead times and fulfill your orders as quickly as possible. You are not required to wait more than 2 weeks for your requirements to be met.
Custom Orders
Customization of services is our priority. Since we are focused on building a long-term customer relationship, we always provide our services with a personal touch. Get in touch with one of our salespersons if you have a custom order or have any queries.
Warranty & Refund Policy
We offer a 30-day refund and a 1-year warranty that covers everything except labor. If there is a problem with our product, you can get a full refund. In fact, we will replace the entire product if the situation demands so.
Full warranty terms are available on our Product Warranties page.
Free Quotes
Last but not least, we can provide you with a full quote should you want one before availing our services.
Get in touch with us now if you are looking for high-quality lighting products made of cast aluminum.
Frequently Asked Questions
Why is aluminum used for casting light poles and signage?
Aluminum is lightweight, resists corrosion through the natural aluminum oxide film that forms on its surface, conducts heat and electricity well, and is fully recyclable, all of which make it well-suited to outdoor streetscape products that need to last for decades.
What’s the difference between sand casting, gravity casting, and die casting?
Sand casting forms a new sand mold for each part and is well-suited to lower production volumes and larger shapes. Gravity casting uses a reusable permanent mold and gravity alone to give a more consistent finish at moderate volumes. Die casting injects molten aluminum into a steel die under high pressure, producing the smoothest finish and finest detail at higher production volumes.
How long does aluminum casting take to reduce machining costs?
Because aluminum casting produces smooth, flat surfaces that are often free of taper or draft, secondary machining is significantly reduced compared with other manufacturing methods, thereby lowering overall production costs.
What warranty comes with Brandon Industries’ cast aluminum products?
Brandon Industries offers a 30-day refund window, a 1-year warranty covering everything except labor, and will replace a product entirely if the situation requires it.
How quickly can Brandon Industries fill a casting order?
Brandon Industries targets lead times of no more than 2 weeks to fill most orders.
