What We Do

Precision Component Manufacturing Experts

We flex our deep knowledge of cutting-edge manufacturing processes to get outsized results in performance and cost reduction for our customers.

CNC Machining

CNC machining (subtractive manufacturing) is a manufacturing process that involves the continuous precision removal of material from a larger piece. From an efficiency standpoint compared with other options, it is best suited to larger parts and those that do not require a substantial amount of material removal.

We offer precision machining across a wide range of materials, part types, and part sizes to extremely tight tolerances. Our machining capabilities include:

CNC lathes up to 6 axis, CNC vertical and horizontal machining centers up to 5-axis
Turning up to 23.62″ diameters x 80″ length with barfeed up to 3.180″ diameter
Milling up to 50″ X-axis, 28.7″ Y-axis, 34.6″ Z-axis
Grinding and honing

Conjured also manufactures custom gears, including gear cutting, hobbing, shaping, and shaving

Metal Injection Molding (MIM)

Metal Injection Molding (MIM) involves mixing powdered metal with a binding material to form parts, which are then cured and sintered. Curing removes the binder while sintering to just below melting point fuses the metal particles together, resulting in a fully dense and consolidated metal part with the desired mechanical properties.

MIM is particularly good for efficiently producing small, complex, and intricately shaped parts with high precision in high volume. It offers cost savings compared to machining such intricate components. MIM is utilized in various industries including aerospace, automotive, medical, and electronics.

Typically MIM involves large up front tooling costs and high Minimum Order Quantities (MOQ). However, Conjured often is able to produce these styles of parts with no tooling and MOQ requirements. Get in touch with us to learn more.

Castings

Casting involves shaping molten metal with a mold and allowing it to solidify into the desired form. It is a versatile process and enables the efficient production of large, complex, and detailed parts that would be challenging or expensive to create through other methods.

Our executive team works extensively with castings for customers across a wide variety of industries, with a wealth of experience in particular working with customers who are industry leaders in the rotating equipment/flow control industries.

Conjured offers castings in a wide variety of materials and processes, including sand castings and investment castings in iron, steel, stainless steel, brass, bronze, and copper. In many cases, we are able to help mitigate or eliminate what is typically a large up front cost of the pattern from which the mold is made.

Additive Manufacturing

Additive manufacturing (AM) is the process of creating three-dimensional objects from a computer file by adding a material layer by layer – also known as 3D printing.

It is a disruptive, evolutionary technology that is changing how we create – from the conception of an idea and initial design to how we acquire raw material for production and get the finished good into the hands of the end consumer.

We are innovators with experience in the world’s most demanding sectors of the manufacturing industry – AM offers a unique opportunity for us to rapidly drive progress. By developing our own proprietary systems built around AM’s limitless possibilities, we can rapidly design, iterate, and produce as needed.

KEY ADVANTAGES OF ADDITIVE MANUFACTURING

SPEED

Rapid prototyping is the capability of designing, manufacturing and testing a customized part within a minimal timeframe. The functionality enabled by AM means that almost anything can be created without the need for a warehouse full of many different types of machines. This also means the typical delays associated with outsourcing intricate manufacturing projects are avoided. The capabilities offered by AM translate into freedom from minimum order constraints, while also enabling large production runs. It allows for effortless creation and customization of parts and products in whatever quantities are required.

QUALITY

The inherent nature of AM requires the incremental construction of parts or products, ensuring improved designs and higher-quality outcomes. In contrast, part manufacturing for traditional methods can often lead to subpar designs, and consequently lower-quality prototypes that require more iterations.

COST

With AM, there is significantly reduced waste as parts are built layer by layer rather than removing material from a starting piece as in subtractive manufacturing. There is also no need for additional tooling as with CNC machining. Typically complexity does not incur extra costs and the number of individual parts requested for an assembly can be reduced by combining them into single components. Traditional manufacturing methods like CNC machining and injection moulding can be significantly more expensive as a result of the cost of additional machinery and associated skilled machinist labour required to meet customers’ particular needs.

ACCESSIBILITY

The actual part-building process of AM is highly automated, minimizing the need for additional personnel to operate, supervise, and maintain the machine. This significantly enhances its accessibility compared to other manufacturing systems and allows available labour to focus on engineering tasks, such as part design optimization.

FLEXIBILITY

AM offers the ability to create and fabricate geometries that are impossible to produce using traditional methods. This includes the creation of intricate single parts, as well as the incorporation of hollow cavities and nested parts within a structure. AM enables users, even those with limited CAD experience, to easily modify designs and generate unique, customized parts. With traditional manufacturing, each new part or part revision often requires new tools, moulds, dies, or jigs to create the new part while AM requires none of these.

SUSTAINABILITY

Fewer parts need outsourcing for manufacturing. This results in less environmental impact as fewer items are transported across the globe. Energy utilization is substantially lower than that of a traditional factory manufacturing similar components. Material for AM is powder-based rather than bar stock as in CNC machining, eliminating the need to order, have shipped, and stock varying geometries of raw material. This significantly reduces supply chain burden as trucks are kept off the road and consequently from emitting harmful emissions. In terms of the byproducts of the manufacturing process, AM creates much less waste and leftover material can be reused rather than discarded as scrap, which means less unnecessary mining of our planet’s precious natural resources.

OUR PORTFOLIO FOR ADDITIVE MANUFACTURED METAL PARTS

Metal Materials Currently Available

Niobium

Titanium

Copper

Stainless Steel

Inconel

Aluminum

OUR SOLUTION

In addition to our CNC and AM production capabilities, we developed a core competency in Design for Additive Manufacturing (DfAM). Conjured is perpetually building this capability, utilizing our expertise to seamlessly transition elements of our customers’ part catalogues to AM compatibility.

By using AM alongside traditional manufacturing methods, we help solve the inherent skilled labour shortage and cost of increased part complexity issues that come with them. AM reduces lead times, eliminates tooling costs, streamlines supply chains, and enables the production of parts designs that were previously unattainable through traditional manufacturing methods.