Estell Group LLC, The

Fishers,  IN 
United States
http://www.theestellgroup.com
  • Booth: 100


Castings, assemblies & machined components for your success!

The Estell Group supports the success of power transmission OEMs with engineered castings, precision machined components, assemblies & sub-assemblies from globally competitive sources in the U.S., Italy, India, & Vietnam. Key areas of focus:

  • Machined & as-cast forgings, gray/ductile iron, ADI, steel & stainless steel castings:
    • Green sand molding to 300 lb.
    • Airset molding up to 25,000 lb.
    • Investment casting to 50 lb.

  • Machined & as-cast aluminum & copper alloy castings:
    • Gravity permanent mold aluminum to 75 lb.
    • Permanent mold bronze gear castings to 200 lb.
    • Copper alloy castings to 300 lb.
    • Sand cast aluminum (automated green sand & air set) to 500+ lb.
    • High pressure die cast aluminum, 400 to 1750 ton presses
  • Fully machined bronze worm gear blanks, broached & ready to hob (30 mm center distance & up):
    • Solid bronze & bronze/iron/steel composites
    • Specialty blanks for sector gears and other unique shapes

Kupral SpA specializes in gravity permanent mold aluminum & copper alloys supporting power transmission, automotive, industrial & rail markets.

AFK Foundry specializes in grey & ductile iron castings for the power transmission, pump & valve markets.

Brands: Shuster Corp. Kupral S.p.a. Mumford Metal Products Aarrowcast AFK Foundry Aluminum Foundry of Wisconsin Generation 4 Recycling Chapter Two GN Altech

 Products

  • Composite Hollow Output Bronze Worm Gear
    KUPRAL - Bronze gear cast on to ductile iron or steel forging, offering best-in-class concentricity and assembly....

    • Kupral's highly automated casting and machining processes assure best-in-class bronze gravity casting properties, and machining the entire blank as one piece eliminates assembly/tolerance stack while assuring best-in-class concentricity and bearing locating position for optimal performance.
  • Aluminum Gear Cases & Housings
    Machined aluminum gearboxes, battery cases, and other pressure tight housings up to dimensions of 1 X 1 X 0.5 meter and 100 kg....

    • Kupral's automated gravity permanent mold aluminum casting processes and 5 axis CNC machining meet the most demanding requirements for complex housings used in the marine, industrial power transmission and electric vehicle industries.
  • Grey & Ductile Iron Castings to 250 lb./115 kg
    AFK Foundry in Ripon, WI offers grey & ductile iron castings from ounces to 250 lb./115 kg produced in automated green sand and cope/drag molding processes. CNC machining, paint and assembly also available....

    • AFK Foundry specializes in grey and ductile iron sand castings for high demand mechanical power transmission, construction, agricultural, pump, and valve applications.  CNC machining, paint and assembly are available through internal capabilities as well as trusted partners.  AFK is ready to solve your iron casting challenge!

    Two automated molding lines offer 16"X20" flask size, supporting castings to 40 lb.  Cope/drag molding lines with largest flask sizes of 30"X32" and 28"X38" offer casting capabilities to 250+ lb.  AFK will expand these capabilities with a new 20"X24" matchplate molding line planned for Q3 2026.

    A variety of core making processes offer options to complicated requirements with high or  low volume requirements.

    More important than equipment and capacity is AFK’s commitment to customer service.  In a complex world, nothing is more important than working to solve your challenges.  Let AFK support your team today!

  • Bronze Composite Worm Gear Blanks
    KUPRAL's automated bronze foundry offers chill cast permanent mold gear blanks for industrial speed reducer and specialty applications. Careful metallurgical control and precision CNC machining meet the most demanding requirements....

    • Composite gear blanks produced in Kupral’s automated bronze foundry offer superior value and metallurgical properties for optimal speed reducer performance.  Casting bronze around an iron or steel center reduces total cost and optimizes output strength as well as input efficiency.

    Precision CNC machining by Kupral assures gear blanks are ready-to-hob and then assemble, supporting efficient OEM operations and flexibility.

    Available worm gear alloys include tin, nickel-tin and aluminum bronzes.

Categories

Gear Materials
  • Forgings
  • Gear Blanks
  • Iron Cast, Ductile
  • Near Net Forgings
  • Plastics/Polymers
    • Gear Products
  • Plastic Gear Transmissions
  • Plastic Gears
  • Racks
  • Worms and Worm Gears
    • Services
  • Assembly
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