The engineers are able to pre-determine scrap issues prior to production with solidification simulations and as a result they have been able to reduce the amount of scrap produced at start up of a new product launch. To help design casting models, BCI also creates prototypes and production models using MagmaSoft solidification software. Once the metal has been cast and shaken out, the products flow through the state of the art cleaning room (mill room) then on its way to the CNC machining centers. A Cupola and medium frequency furnaces are used at the foundry for melting recycled materials to be poured into green sand molds produced by match plate molding machines. In 2011 BCI opened its 55,000 SFT facility to house all machine centers and host all assemblies.īremen Castings also creates prototypes using solidification software and runs solidification simulations as a means of scrap reduction.īremen Castings foundry produces castings made from recycled materials such as plate and structural steel and old cast products. BCI purchased its first CNC machines in 1996 and now has over 17 CNC machines in its arsenal.īCI continues to grow. This gives BCI the advantage for both departments to communicate before the product launch for a lower total start up cost. This forced quality and engineering to grow to be diverse in both machining and foundry. In 1996 BCI launched its own internal machine shop with the new addition of a 15,000-square-foot (1,400 m 2) facility to the existing foundry with the expectations to diversify across many markets. īCI Defense began in December 2012 and currently manufacturers firearms and Firearm parts from 7075 aluminium alloy, specifically the AR-15 style rifle. The foundry's machine shop opened in 1996 and the tool shop opened in 2009. Starting in the mid-1990s, Bremen Castings started to expand beyond casting. In 1972, the company changed its name to Bremen Castings, Inc. All of these early suppliers are still in business today and continue to have close relationships with BCI. Pfeiffer Construction who helped build the foundry and install equipment, and Koontz Hardware where various supplies were purchased. Suppliers included Hurwich Iron where they purchased cupola/steel materials, I.O. The foundry originally produced fire pots, stove parts, furnace, shaker, and laundry grates for its customers. Bremen Gray Iron Foundry was founded on Maby Ellis Brown, Charles W.
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