Modern Casting magazine features our commitment to growth in their October 2022 issue. Our new melting system, shakeout system and the molding line have allowed us to make significant improvements in our efficiencies. Along with the addition of a new FBO-IIIS molding machine and integrating MAGMASOFT ® into our pattern shop we have elevated our customer experience. We produce cored casting jobs, pattern designs, pattern layouts, austempering, gating and risering all in-house. Every investment in growth is an investment in our customers through competitive pricing and flexible capacity. For more go to, https://www.moderncasting.com/articles/2022/10/06/farrar-sets-growth
Farrar is excited to announce that our state-of-the-art pattern shop has invested in MAGMASOFT®, an innovative foundry engineering software. Pattern shop personnel will have completed initial training by August 22, and Farrar will begin to utilize the software in the coming weeks.
MAGMA, a company that has been a staple in the metal casting industry since 1988, is a trusted worldwide developer of casting software. This software offers solidification and flow analysis capabilities while giving our team the ability to optimize tooling designs prior to sampling.
“Our investment in MAGMASOFT® will allow us to effectively produce quality castings with optimized tooling designs,” said Chad Allender, Farrar’s Pattern Shop Engineering Supervisor. “We look forward to the reduction in production costs this will bring as we optimize existing jobs. This simulation software will reduce the ‘trial and error’ when sampling new jobs and allow us to mitigate potential defects during the initial design rather than during sampling. “
Farrar’s team of engineers provides customers with a flexible design process to meet the specific needs of each project.
MAGMASOFT® will only elevate that process, in addition to Solidworks 2021 and MasterCAM, which are the two other programs our pattern shop utilizes.
The software upgrade continues the trend of improvements that has been prevalent at Farrar in the past few years. Earlier this spring, we installed a cutting-edge FBO-IIS 20 x 24 molding line from Roberts Sinto that will increase the capacity of our ductile iron foundry. Other recent capital investments include two new 2500KW Inductotherm coreless induction furnaces that were installed in early 2019 and two DMG-Mori NTX 5-axis CNC machining centers that were added in late 2019 and early 2020. We have also invested in upgrading our shakeout system, including new conveyors and a media drum.
Continuous improvement is one of our core values and we are committed to finding new ways to enhance our products, pricing, and lead times for our loyal customers.
If you are interested in using Farrar for your next project, visit our contact page to request a quote and get in touch with our manufacturing experts.
At Farrar Corporation, we only pour ductile iron and ductile iron properties for austempered ductile iron (ADI).
That’s because this type of metal has many advantages that best suit the needs of our customers, as we can manufacture products that are of the highest quality and in a cost-effective manner.
Ductile iron was founded in 1943 by Keith Millis, as part of an effort to produce a stronger iron that could be used for the American military in World War II. This type of iron cast contains a secret ingredient — spherical graphite nodules — which is what provides the many benefits ductile iron offers compared to other metals.
Why is ductile iron the choice for you? There are several reasons.
Ductile iron has much higher tensile strength compared to other options such as gray iron. In our foundry, we primarily pour four grades of ductile iron (60-40-18, 65-45-12, 80-55-06, 100-70-03) which equates to tensile strength between 60,000 and 100,000 psi. With the austempering grades we offer (130-90-09, 150-100-07, 175-125-04, 200-155-02, 230-185-01), that strength level rises between 130,000 and 230,000 psi.
Because of the spherical nodules, ductile iron has superb wear resistance and elongation properties. This versatility allows for varying elongation within designated iron types, which allows end users to design their product in the most efficient and cost-effective manner; selecting a needed strength complemented with a needed elongation.
Despite its toughness, ductile iron’s strength-to-weight ratio stands apart from other metals. Therefore, these castings have become the popular choice for products that need to be lightweight but maintain strength. This is one reason why the automotive industry, agricultural industry and the heavy truck industry rely heavily on ductile iron.
Compared to products such as steel, ductile iron offers an efficient manufacturing process which allows it to be more affordable for customers.
“Quality ductile iron comes from quality raw materials. At Farrar, we have strict parameters around our scrap steel, minerals/additives/inoculants, sand, and other critical path raw materials. This gives us the ability to control the chemistry and ensure the properties you buy are exactly what you specified.”Scott Case, President/CEO of Farrar Corporation
If ductile iron sounds right for your next project, visit our contact page to get in touch with our manufacturing experts.
One aspect that sets Farrar apart from the competition is our vertically integrated production model. This means we control each stage from start to finish, ensuring your product is delivered on time and with the highest quality. Our streamlined pattern shop, foundry, and CNC machine facilities enable us to deliver a complete range of manufacturing solutions. Vertical integration brings with it several advantages, including pricing, on-time delivery, quality products, responsiveness, and creative solutions.
The process begins with our custom pattern-making services. We insist on designing and manufacturing our own patterns in-house because we believe the finished quality of a ductile iron casting is determined by the quality of the pattern from which it’s cast.
Our pattern shop contains advanced CAD/Engineering Software and CNC machining equipment including a Hurco VMX64 CNC Mill, a Hurco VM CNC Mill, and a Mori-Seiki SV-500 CNC Mill. The shop is backed by innovative engineering and design technology such as Solidworks 2021 and MasterCAM, with a new software in MAGMASOFT coming to Farrar in the summer of 2022. This new investment will offer solidification analysis and flow analysis while allowing us to optimize tooling designs before sampling.
Once the pattern is produced, the next step occurs in our state-of-the-art foundry where we pour 70 tons of ductile iron every day. Our foundry is outfitted with automated molding technology from Roberts Sinto, including two 20” x 24” FBN models and a new 20” x 24” FBO model that will increase our production capacity. We offer a wide range of weights, sizes, and pouring grades to best meet our customers’ specifications.
Farrar also has two machine shops equipped with CNC machining centers from DMG-Mori, Okuma, and Haas. The facilities are streamlined for optimum production of the exact size and weight of castings we produce for OEMs and other large-run manufacturers, which equates to maximum production efficiency for your products and minimum turnaround times on custom patterns and castings.
For customers who need their castings annealed, we provide heat treatment services. Our facility includes three fully programmable furnaces along with a fully automated material handling system to deliver fast and efficient processing.
We also offer expert assembly and finishing services, no matter the level of complexity, to take your product to the finish line.
With Farrar, you don’t have to worry about scheduling nightmares with outside vendors, unexpected shipping costs, poor customer service, and low-quality products. From prototype to assembly, from design to delivery, we are there every step of the way to ensure the needs of the customer are met in a timely and cost-effective manner.
We continue to evolve our services to provide customers with industry-leading results and are proud to be a one-stop shop for your ductile iron needs. Visit our contact page to get in touch with us and get started on your next project.
Farrar Corporation was founded in 1933, by Ernst Clifford (E.C.) Farrar, as a blacksmith and repair shop in the small town of Norwich, Kansas. E. C. Farrar had a talent for fixing things, and he used that skill to serve his rural community. Almost 90 years later, that single shop on main street has evolved into a foundry, a custom pattern shop, a CNC machining facility, along with corporate offices, and a secondary CNC machining facility across the state in Manhattan.
Today, Farrar is a leading supplier of ductile iron castings and quality machined components thanks to our core values of integrity, stewardship, teamwork, continuous improvement, commitment to creative value, and emphasis on long-term customer relationships, all of which have been embedded into the company since day one.
There is a strong sense of pride that radiates through Farrar because it was built on small-town roots, a persistent work ethic, and American ingenuity.
The answer to how we became a leader in the industry starts in the 1950s, which saw the first shift in the company that would lean us heavily into farm repair. E.C. Farrar’s sons, Max and Paul, joined the family-owned business after serving in the Army during World War II and helped develop improvements for combines including the highly successful sickle drive, a contribution that is a prime example of the type of innovation and forward-thinking that have always been ingrained into the DNA of Farrar. This led to a focus on various parts for farm equipment and we became a popular spot for farm repair across the region.
Soon after this shift, it became clear that pouring our own ductile iron was the next logical step. Doing it in-house would be cheaper and give us more control over the parts. So, in 1967 the foundry was opened in Norwich.
The success of this move was so apparent that planning to expand and remodel the foundry began. Joe Farrar, who would become a longtime president of the company later in his career, designed the foundry that resembles the one you see today back in 1974.
In the following years, the farm repair business model began to weaken, and a drastic overhaul of Farrar would start to take place. 1988 became a landmark year for the company as we dropped our own product line to focus only on providing cast and machined parts to O.E.M customers. This transition was overseen by Joe, who took over as president that same year.
By the late 90s, it came time for another round of expansion. When the search for new land adjacent to the Norwich campus hit a dead end, Joe started to entertain the idea of expanding the company to a separate location. Through a long decision process, Manhattan, Kansas became the chosen destination due to the city’s exciting bid, geographical benefits, and cultural fit. Not to mention, the Farrar family has a long history of devotion to the Kansas State Wildcats. New corporate offices and a state-of-the-art CNC machining facility were constructed and opened in Manhattan in 2000.
These changes have shaped us into who we are today, which is a vertically integrated manufacturer that provides the highest quality products, services, and turnkey solutions to our loyal customers.
Though we are proud of our past, we are even more excited about the future under the leadership of our new president Scott Case. The recent investments in a 2,500 KW Inductotherm coreless induction furnace and now a new FBO-IIIS 20 x 24 from Roberts Sinto molding line bring new capabilities to our foundry so we can continue to provide our customers with the very best products and service in the industry.
If our history of innovation, hard work, and a commitment to improvement is any indication; then we’re just getting started.