Written by: Jason Palmer, Delta Motion
Above: Delta hydraulic motion controllers can improve press cycle times by 10 to 20 percent in trim operations
March, 2026- A precise trimming operation is critical for cast components. It prevents structural interference, reduces post-processing labor and ensures parts meet dimensional accuracy, proper fitment in assembly and superior surface quality.
Advanced Foundry Specialists (AFS) designs and builds trim presses used to process castings across a wide range of applications, many of which are mission critical.
“Some of the world’s leading automotive manufacturers rely on customized AFS hydraulic trim presses to finish molded parts,” says AFS Vice President and General Manager Brian Luebke. “In this process, precision is non-negotiable. Customer quality requirements are understandably strict, and any failure in the trimming operation can have serious consequences. A defective part, such as a cracked brake caliper, could ultimately put lives at risk.”
BREAKING BARRIERS
To meet customer demands, AFS made significant improvements in both accuracy and cycle time by adopting motion controller solutions from Delta Motion. In vertical molding operations, the upper and lower molds close together to form the casting.
Where the molds meet, a thin line of excess material known as flash is created and must be removed with high precision. Grinding is a slow and labor-intensive process. A trim press offers faster and more consistent results, particularly for high-volume production. However, increasing throughput requires running presses at higher speeds, which can introduce risk. Without precise motion control, a trim press can crash, potentially damaging tooling or equipment.
In the past, AFS relied on PLC-based control for trim press motion. Due to the inherent limitations of PLC programmability, operators were unable to stop the press accurately while running at optimal speeds. This forced a compromise between production speed and positioning accuracy.
To help solve these challenges, AFS evaluated multiple digital motion controller brands and explored different approaches, including retrofitting advanced sensors onto PLCcontrolled presses. Some systems used laser-based detection to identify load placement issues, but these solutions were cost prohibitive for the application. Delta motion controllers were able to provide response time and control performance improvements. AFS adopted the technology for its trim press designs.
REAL TIME
Transitioning to Delta hydraulic motion controllers also helped AFS address the risks associated with misloads. Parts that appear nearly cylindrical can easily be loaded incorrectly due to operator fatigue or distraction. A slightly flattened feature positioned at the wrong orientation in the trim press can damage the part and may even harm the tooling or press itself.
AFS equipped its trim presses with Delta motion controllers and high-resolution linear position transducers, allowing the system to continuously monitor tooling position and movement in real time. If contact does not occur as expected, the system can detect the issue immediately and stop motion before damage occurs. To meet production requirements, the presses typically run at approximately 10 inches per second.
AFS has installed more than 30 customized trim presses using Delta motion controllers.
“Depending on the job specifics, Delta motion controllers have improved press cycle times by 10 to 20 percent,” says Luebke.
Performance gains are meaningful, but product quality improvements remain a priority. A single process fault can lead to repeated defects across multiple parts, increasing the risk of costly recalls. The level of preventive quality control enabled by Delta’s motion control technology significantly reduces these risks and lowers return rates for finished components.
ADVANTAGES
“The biggest benefit to us in having this layer of protection is that automakers, foundries– our customers–had steered away from trimming, even though it provided more consistent parts,” says Luebke. “They steered away because of the risk involved in those misloads and what a misload would mean to the RMA rate. But with Delta’s technology, it turned trimming from being a non-starter to a viable option.”
According to Luebke, Delta’s software and technical support are key factors in the successful implementation of the RMC platform. Delta’s RMCTools software, with its menu-driven setup and graphics-based displays, allowed the team to implement complex hydraulic motion control without extensive programming experience.
RMCTools are similar to learning software platforms like Adobe or Microsoft. Initial setup is quick, taking anywhere from minutes to hours. But ease of use is only one of the software’s advantages.
“The feature set is so deep,” says Luebke. “You can’t expect to know it all in a year or two. I have zero controls background and little experience with programming languages. But Delta was always there to hold our hands and teach us what was possible with its software. We’ve had so many design challenges over the years, and Delta would give us ideas on what to try and how to implement it. As a result, the feature set we can offer to our customers has steadily broadened as we have gained experience with the system.”
To date, AFS has installed more than 30 customized trim presses using Delta motion controllers, and customer acceptance continues to grow. Ultimately, advanced hydraulic motion control has allowed AFS to deliver faster production, a more cost-effective overall solution and improved safety for end users worldwide.
Advanced Foundry Specialists, 920/954-5800, withats.com
Delta Motion, 360/254-8688, deltamotion.com
