ALUMINUM BRONZE FOUNDRY FROM DESIGN TO MACHINED PARTs

An integrated process designed to prevent industrial issues

In a traditional organization, foundry and machining are separate.

Defects often appear too late, during machining.

These situations generally lead to:

returns to the foundry
extended lead times
additional costs

At Davergne, these constraints are integrated from the outset, and deviations are corrected continuously.

Result: problems are anticipated and corrected before impacting your parts.

Engineering Department

Design tailored for foundry and machining

Our engineering department designs parts by integrating real production constraints from aluminum bronze casting and machining from the very beginning.

We don’t just create CAD models —
we develop parts that are directly optimized for industrial manufacturing.

Equipped with 4 CAD workstations, our engineering team works in close collaboration with the workshop to validate every technical decision.

Design parameters taken into account:

casting constraints
material shrinkage
sensitive areas
machining allowances

Result: parts ready for industrial production from the design stage, with no late adjustments or production deviations.

In-house prototyping and 3D printing to validate before industrialization

PROTOTYPING

We produce your prototypes in-house, particularly using 3D printing, to quickly validate technical choices before tooling is manufactured.

This stage allows us to compare the design with the real part and align the engineering department, mold manufacturing, and production.

Prototyping makes it possible to:

validate geometry and functionality
anticipate manufacturing constraints
refine technical choices upstream

Thanks to direct interaction between departments, adjustments are made immediately.

Result: a secure development process and a smooth transition to production without deviations.

Tooling Workshop

In-house manufacturing of molds and tooling

We design and manufacture all our tooling in-house:

foundry molds
cutting tools
machining tooling

Unlike a fragmented organization, our tooling is developed in direct collaboration with the engineering department, the foundry, and machining.

They are not fixed — they evolve based on production feedback and the functional requirements of the parts.

This interaction enables:

rapid adjustments
continuous mold optimization
improved control of tolerances

Result: compliant parts from the first production runs and faster process stabilization.

Foudry Workshop

ALUMINUM BRONZE FOUNDRY

We cast aluminum bronze parts, a material known for its mechanical performance and corrosion resistance in demanding environments.

Our foundry workshop relies on adapted production capabilities:

melting and holding furnaces
gravity die casting
small and medium batch production

With over 80 years of experience, our foundry has strong expertise in material behavior and production constraints.

This experience is directly leveraged within our integrated organization.

Foundry parameters are adjusted based on:

requirements defined by the engineering department
tooling constraints
machining conditions

This interaction makes it possible to anticipate potential defects (shrinkage, porosity, inadequate machining allowances).

Result: controlled metallurgical quality and parts directly suited for machining.

TESTING LABORATORY

Metallurgical control and alloy mastery

Our testing laboratory monitors the composition and properties of aluminum bronze at every stage of production.

We carry out in-house:

spectrometric analysis
mechanical testing (tensile strength, hardness)
batch tracking and traceability

This control goes beyond material compliance.
It is part of a comprehensive process control approach.

Metallurgical characteristics are directly correlated with:

casting behavior
mechanical performance
machinability

Thanks to close interaction with the foundry and machining, adjustments are made immediately when necessary.

Result: controlled alloys, reliable machinability, and parts that meet specifications.

Cutting workshop

Cutting integrated into the production flow

Cutting operations are carried out in-house, in direct continuity with the foundry.

We design and use specific cutting tools for each part.
Today, more than 90% of our parts have their own dedicated tooling.

This ensures:

consistent precision

repeatability in production

perfect adaptation to part geometry

Integrated into the overall process, this stage avoids any disruption in the production chain.

Adjustments can be made immediately in coordination with the foundry and tooling workshops.

Result: controlled cutting operations, fully aligned with the overall process and without external dependency.

Machining Workshop

Integrated machining: full control of finished parts

Machining is not just a final step — it is a key driver of process control.
It is carried out in-house, in direct continuity with the foundry and tooling. This integration ensures part compliance from the moment they are produced, without relying on external subcontractors.

We are equipped with suitable machining capabilities:

multi-axis machining centers
secondary operations and finishing
small and medium batch production

However, machining is not an isolated step.

It is directly connected to the other workshops:

foundry parameters are adjusted based on machining feedback
tooling evolves according to encountered constraints
design choices are validated on real parts

Unlike a traditional organization, no part moves back and forth between multiple suppliers.

Deviations are identified and corrected immediately in-house.

Result: elimination of back-and-forth between foundry and machining, controlled lead times, and fully mastered part quality.

Quality

comprehensive quality control across the entire process

Our quality system covers the entire process, from design to the finished machined part.

Unlike organizations involving multiple suppliers, control is not limited to the final part.

Each stage is monitored and validated:

design
tooling
foundry
machining

We carry out in particular:

dimensional inspections
production monitoring
compliance verification

This approach makes it possible to identify deviations at their source, rather than at the end of the process. Our organization is based on a structured quality system (ISO 9001) and follows a continuous improvement approach, with the objective of ISO 14001 certification.

Responsibility for quality is unified and fully managed in-house.

Result: consistent quality, improved traceability, and parts compliant from the first production run.

ERP / Production Monitoring

Process tracking and traceability

Our ERP system enables us to manage and monitor all stages of production, from raw material to the finished machined part.

Each operation is tracked:

tooling manufacturing
foundry
machining
inspection

This traceability ensures a global view of the process and consistency across all stages.

Thanks to the integration of all workshops, information flows seamlessly and adjustments can be made quickly.

Result: reliable tracking, improved responsiveness, and fully controlled production.

Gender Equality Index

As part of our HR policy, we monitor the professional equality index between women and men.

2025 INDEX : 92/100

Pay gap: 38/40
Individual salary increases: 35 / 35
High salaries: 5 / 10

This indicator is part of our overall continuous improvement approach

Integrated aluminum bronze foundry for industrial parts

Located in Picardy (France), Davergne designs, manufactures, and machines aluminum bronze parts for demanding industrial applications.

Thanks to our fully integrated organization, we control the entire process — from design to the finished part.

A single point of contact, controlled quality, and optimized lead times.

ENGINEERING DEPARTMENT

tooling WORSHOP

Foundry

Cutting

Machining

Quality
control

Did you know ?

Each high-speed train contains around 20 tons of copper-based components, particularly in current collection systems and electrical equipment.

These applications require materials capable of withstanding high mechanical, thermal, and electrical stresses.

Aluminum bronze alloys are used for their strength, long-term performance, and reliability in demanding conditions.

Davergne has been active in the railway sector for several decades, working with major players such as SNCF to manufacture aluminum bronze components.