Located in Muskegon, MI, Port City Group is the newest addition to Pace Industries. Pace and Port City Group merged operations in July 2015, with great enthusiasm for many reasons. A unique characteristic of this new facility is that it is comprised of several locations – six fully-integrated companies.  This division includes four die casting plants, custom plastics manufacturing and specialty tooling.

Through Port City Group, we are proud to not only continue serving the automotive industry, but we also offer capabilities to the recreational vehicle, meters and lawn & garden industries. No matter who the customer is, we insist on beginning our relationship by assigning them an engineer who will be present during each cycle of their project. Because of this consistency in personnel, we can reduce time and cost for our customers.

Pace Port City Group specializes in full-service supply chain management and providing tooling design and management to customers. Boasting 31 die cast machines, our capabilities include high pressure die casting, complex machining, plastic injection molding, tooling, rapid prototyping, and product design and validation. The products we create range in weight from .05 to 20 pounds. We have a wide range of tools at our disposal, which is what allows us to produce such a variety of products.  We successfully work with flow analysis, thermal analysis, nanotechnology and several other in-house tools. Mirror Image Tool is the specialty tooling company that offers design and construction of secondary machining equipment as well as inspection equipment.

A capability we are particularly proud of is producing complex parts sensitive to specific porosity and cosmetic requirements. It is a task we are good at and, therefore, are often asked to do it for customers. Once we have confirmed that we have supported design work, we efficiently make these delicate parts.

To exceed the expectations of the customers we serve, PCG has a strict Quality Management Systems in place that we are deeply committed to. Whether we are manufacturing aluminum die castings, mechanical assemblies or injected mold plastics, the promise to our customers is the Pace Advantage of delivering the highest quality products in the most efficient amount of time.

This month, we continue to celebrate Pace Industries’ wins at the North American Die Casting Association’s (NADCA) International Die Casting Design Competition. We are recognizing our Saltillo Division for their victory in the Aluminum Die Casting category for parts weighing 1-to-10 pounds.

Alfonso Carillo, sales manager at the Saltillo Division, thought carefully about the product his team would submit, ultimately deciding to showcase the complex high-bay LED heatsink. “This is a heat dissipater, which is usually a challenge for a die caster,” said Carillo. The high-bay LED heatsink is made to be used in warehouses, or other structures with high ceilings. Because LED lights generate a considerable amount of heat, the heatsink’s function is to help dissipate heat and help lights cool down.

The development of the LED heatsink has been quite a journey, and we are happy that we were given the opportunity to become involved and active in its later stages of production. The Saltillo Division began working on the part with our customer, Cree, in 2015. When they brought the design to us, we knew that it was a great product, but could benefit from some changes. In collaboration with their design team, the Saltillo Division further enhanced the LED heatsink and worked to improve the functionality. By early 2016, we were able to provide a better solution for the customer that eliminated several components which resulted in a high level of heat conductivity.

Nelson Lui, senior mechanical engineer at Cree industries and the original designer of the part, is both surprised and excited about the recognition that the heatsink has received. “I understand this component is not easy, but Pace has good engineers,” said Lui. He and his team worked hard to develop this part, and he was always grateful for their support and professional advice. This open exchange has also existed in our relationship with Lui. “I had never thought of the modifications before, but after they mentioned it, I was confident about the changes, although it is our most complex part.” When he was consulted about granting permission to enter it for a NADCA award, he had no hesitations. Our relationship with Cree has been active only since January 2015, but Lui believes in the future of our collaborations.

“This win brings pride,” beams Carillo. “It is going to help us because it’s a valid way to prove to a customer that we are concerned about the final product.” This is a great example of Pace’s commitment to provide uncommon solutions that contribute to the success of our customers. Carillo states, “An award like this shows we are able to respond quickly to the demands of the market with quality work. It’s a game changer for any company.”

A 2016 Honda Odyssey, which includes the winning part from Port City Group.

A new experience is where growth happens, and it is a bonus if success happens on your first attempt at it. That is exactly what Port City Group accomplished last month when we entered the North American Die Casting Association’s (NADCA) International Die Casting Design Competition. This was our first year to submit an entry, and the risk paid off when we took home the prize for Best Aluminum Die Casting Under One Pound.

The annual international competition, held the last 43 years, promotes increased use of die castings through the recognition of outstanding designs. The competition showcases outstanding die cast designs, while acknowledging the continuous contribution die casters provide to the manufacturing industry.

Entries this year came from the U.S., Canada and overseas. Some of the additional winners were from Italy and Austria. Each entry was judged on its ingenuity of design, quality, cost savings and industry-changing potential. Winners are featured in national industry magazines (including Die Casting Engineer) and are displayed at the 2016 Die Casting Congress & Tabletop.

Pace’s Port City Group won in the aluminum category for our side mirror inner base, manufactured for our customer Magna Mirrors. This innovative design differs from methods previously used to attach side mirrors on cars, most notably by minimizing post processing and eliminating a machine operation.  This gives our customer a distinct industry advantage.

When deciding what parts to enter, we looked at several unique parts that Port City Group has developed and agreed that we should pick something that gives our customers a commercial advantage or that solves for an existing problem. We are proud of our side mirror inner base part and the recognition it and our team members have received. It serves as an excellent example of our continuing and unwavering commitment to providing creative and uncommon solutions.

We look forward to competing again in the NADCA awards. It is an excellent way to showcase our everyday work on a grander scale. Our top priority is, and always will be, the manufacturing of innovative and quality products that we take pride in. And a satisfied customer is always the biggest reward. However, there’s no denying that being labeled a winner is also a nice perk.

For the past 24 years, the Pace Industries Cambridge Division has participated in the regional Design-2-Part (D2P) show. As our mission statement proudly states, we are always seeking opportunities to provide uncommon, creative die casting and support solutions for our customers. Here at the Pace Industries Cambridge Division, we pride ourselves in serving niche and specialty markets with our complex die castings and engineering support. As Northeast sales manager Jeff Martin puts it, “We provide uncommon value in the market niches we elect to serve.” Those who have worked with Pace Cambridge are aware that low volume, highly complex projects, such as sub-assemblies, is where this division thrives. This show is a chance for us to increase visibility with those who have not discovered us yet.

On September 28 and 29, the Pace Industries Cambridge Division participated in the regional D2P held at the Royal Plaza Trade Center located in Marlborough, Mass. The more than 1,800 attendees were able to see both custom and stock parts, components and services from over 300 manufacturing categories. Exhibitors came from all over the country, spanning from California to Maine. Northeast Sales Manager Jeff Martin attended the show this year. He was excited to see how active the local market was, and in the two days Pace Cambridge was present, we feel great about the connections we were able to make.

The goal of D2P is to connect job shops and manufacturers face-to-face with OEM engineers, management and buyers who need their expertise and services to solve manufacturing challenges and improve the quality of their parts. Martin recalls an instance from a past show in which Pace Cambridge was able to connect with an engineer who was working with the thermal efficiency of his products. “We were able to suggest a specialty alloy, which provided the margin to improve thermal performance,” said Martin. “This led to an immediate transfer of tooling to Pace Cambridge.”

So what do we do now with our newfound experience and knowledge? In the past, attendance at the show has resulted in increases in sales up to five percent. Our main goal in attending the show is to bridge the gap for many of the attendees of the show who don’t think their projects need die casting. “We witnessed interest and are in the process of following up,” said Martin. “My key takeaway is that the local market is vibrant with activity.”

Located in Arden Hills, Minnesota, the St. Paul Division of Pace is proud to produce aluminum die castings for complex, difficult-to-fill parts with a focus in flash-free, net-shape production. From concept to solution, our high quality approach ensures that all the aluminum die cast components meet exact design specifications and are delivered on time and within budget.

With 11 aluminum die cast machines, this division of Pace Industries specializes in providing custom alloys and machining for a diverse customer base, including the medical equipment, aerospace, recreational vehicles, instrumentation, automotive, defense, and motors and industrial industries. As a TS-certified and ITAR participating facility, we offer value add services, including full in-house product assembly to alleviate time and space constraints for customers.

The St. Paul division offers a wide array of services and capabilities to meet the needs of customers, including:

• Robotic cells
• Vacuum units
• Vibratory machines
• Custom machine fixtures
• Central shot monitoring systems.

Additionally, we are committed to transforming our customers’ concepts into functional die casting solutions through the utilization of tools such as flow analysis, thermal analysis, computational fluid dynamics and nanotechnology.

When we deliver our final products, customers know they’re getting top quality work that is the result of the latest die-casting technology, rigid standard of performance and the pride of remarkable workmanship and outstanding service.

We invite you to learn more about the St. Paul Division on October 14 as we celebrate Manufacturing Day. We’ll open our doors for tours of the facility, as well as a presentation about Pace Industries and some of the products manufactured here. Please contact Ethan Robinson at Ethan.Robinson@paceind.com if interested in attending. We look forward to seeing you there!

The Cambridge Division, located in North Billerica, Mass., is one of Pace’s longest-running facilities. Founded in 1945, Cambridge has been providing contract manufacturing die casting worldwide for more than 70 years. Three facilities with over 300,000-square-feet combined space provide a large environment for expert manufacturing services. Cambridge focuses on value-added services, producing higher-end components and serving a number of different industries.

This particular division excels in serving niche and specialty markets by expertly producing difficult die castings and providing exemplary project management and engineering support. Taking it a step further, Cambridge offers in-house product assembly, machining and finishing to create a total solution. The division is also ideally positioned to serve design houses that assist innovative customers and start-ups in the medical, aerospace, instrumentation and defense industries.

Recently, the Cambridge Division was selected by Civiq Smartscapes as the mechanical manufacturing partner for Link NYC. Link NYC is like an iPhone for the street. It’s the first of its kind and serves as a public access Gigabit Wi-Fi hub providing free Internet access to New York City. NYC is just the first municipality to adopt the Civiq Smartscapes solution.

Through our Cambridge Division, Civiq Smartscapes is able to leverage expertise in mechanical design, casting, machining, product finishing and assembly. Cambridge engineering worked closely with the client to redesign parts and sub-assemblies, which not only reduced costs, but also improved the final finish for superior aesthetics and durability.

Interested in what we can do for you in our North Billerica location? Contact Jeff Martin or Al Parrelli.

Here at Pace, we have been producing Zinc-Aluminum (ZA) alloys for so long, hardly anyone remembers how the company even got started. We rounded up some of our smartest associates and picked their brains to learn more about ZA alloys. Here is what we do know.

Developed in the late 1960s and early 1970s, ZA alloys served to fill a gap in performance characteristics between zinc alloys and aluminum alloys. There are three alloys in this family; ZA-8, ZA-12 and ZA-27. The numbers in the alloy names are the approximate percentages of aluminum in the alloy. As a comparison, the nominal amount of aluminum in standard zinc alloys is 4%.

B&C Die Cast was founded in 1984 as a family-owned and operated business. The company built a reputation as a service, product and quality leader in the industry and, in 1998, became part of the Pace family. The B&C division has been producing ZA alloys for 32 years now, which provide significant benefits to the Pace customers.

The benefits of ZA alloys are vast and include:
• Improved strength
• Improved creep resistance
• Improved hardness
• Improved bearing and wear characteristics
• Lower densities than zinc alloys

We are proud to produce a product with such considerable benefits to our customers. Our B&C division produces castings using the ZA-8 alloy in a hot chamber die casting process. In addition to those benefits listed above, this process saves our customers money by providing a longer die-life — compared to dies running with aluminum alloys. Another financial benefit is that dies can also be interchanged with ZA-12 and ZA-27 alloys, without the need to purchase new dies. In addition to being affordable, we have faster cycle times than standard zinc die casting, making Pace more competitive than other companies.

The B&C division specializes 100% in zinc die castings. B&C also offers in-house machining capabilities and assembly to provide a variety of options to our customers. At Pace, we are committed to providing our customers with the highest-quality products to meet their needs in affordable and convenient ways. ZA alloys are just one way that we are making that happen.

In 2000, the Product Tech Division in Maple Lake, Minnesota, joined the Pace portfolio to expand product offerings – specifically with magnesium components. Even today, the fastest growing market for magnesium is in die casting because it makes products lighter, stronger, electronically sound and reduces vibration.

As the automotive world continues to search for light weighting options for fuel efficiencies, paired with the increasing amount of reshoring activities from China, the Product Tech business is seeing increased opportunities. Additionally, magnesium is highly sought after for medical devices, recreational vehicles, engineering, technology, and power and hand tools. Through Product Tech, we’re able to serve all these industries and more.

 

The Full Solution

We offer our customers an integrated magnesium resource for product development from concept to solution. Our capabilities include:

• Magnesium Die Casting
• Vertical and Horizontal Machining Centers
• Pad Printing Equipment
• Robotic Sanding Equipment
• Custom-built Machining/Assembly Centers
• Custom-built Assembly Machines
• Multi-head Tapping Machines
• CMM Machines
• Full Tool Room Support
• High-speed Hard Milling Vertical Machining Centers
• Sinker EDM
• Precision Surface Grinders

 

Certified Dedication

Product Tech is ITAR registered and fully integrates engineering, prototype manufacturing, tooling construction and volume production activities for a seamless product development experience. And as an ISO-certified division, it incorporates advanced lean manufacturing principles to create additional value for customers.

Another important note is that Pace adheres to intensive early supplier involvement and offers dedicated resources that can embed at customer sites to ensure manufacturing design optimization. This division also offers in-house tooling production and repair, and rapid prototyping to reduce time to market and ensure a more consistent supply chain.

 

Always Looking Ahead

Product Tech is proud to face tomorrow’s challenges today and transform concepts into functional, cost-effective die casting solutions through the utilization of tools such as:

• Flow Analysis
• Thermal Analysis
• Thermal Stress Analysis
• Computational Fluid Dynamics
• Finite Element Analysis
• Patented Process Control for Cosmetic Castings
• Nanotechnology

This division is also in the process of a 60,000 sqft addition to the existing building, which means the available manufacturing space will nearly double in size to a total of 110,000 sqft. This expansion will allow Product Tech to expand in the areas of large tonnage machines and newer technologies that can deliver lightweight products with high structural integrity.

At Pace, we strive to provide unique, creative die casting and support solutions that contribute to the success of our customers. Product Tech is a key component to achieving this mission, and we’re excited to see them continue to grow and innovate.

In 1998, our Chihuahua Division opened primarily to service customers in Juarez. Since then, the operation has grown to service customers throughout Mexico, the United States, United Kingdom and Asia. Our facility offers 210,000 square feet of manufacturing space, and through recent lean initiatives, the operation is well-positioned for additional customers and growth.

One of the aspects of this division that makes it so unique is its geographic location. We service many U.S. corporations that operate in Mexico who need quality die cast solutions. By providing products to clients who are geographically close, we are able to execute a localization strategy that allows us to manufacture high-quality parts at an affordable cost.

Our Chihuahua Division capabilities include machining, simple drill and tap operations to complex CNC operations. We also offer finishing operations including trimming, deburring, shot blasting, painting, chromating, impregnating and more. Value add services include fully machined and assembled components, providing customers a complete solution. With these capabilities, we serve in the automotive, telecommunications, lighting, electrical and industrial controls industries.

The education assistance provided at our Chihuahua Division is what sets this facility apart. In the past 5 years, we provided assistance to allow 60+ people to earn their High School diplomas, approximately 40 people to earn a Bachelor’s Degree and some to achieve a Masters of Business Administration. “An investment in associates is paramount, and that includes a commitment to training and education,” said Doug Walker, Executive VP of Operations in Chihuahua.

Our excellent management team at the Chihuahua Division is constantly working to provide uncommon solutions to our customers. Working together with our customers, we can help develop die casting designs that satisfy functionality and castability requirements and exceed expectations.

 

FAST FACTS
Square Feet	210,000
Certifications	TS 16949 ISO 14001:2004
Alloys	A360, A380, A383, A413
Industries Served	Automotive Industrial Controls Telecommunication Lighting & Electrical
Equipment	29 Die Casting Machines 600-700 Ton – 9 machines 900 Ton – 10 machines 1200-1300 Ton – 8 machines 1650-1850 Ton – 2 machines
Capabilities	Vertical & Horizontal CNC Machining Centers Custom-built Machining Centers Assembly Fixtures Impregnation Chromating Lines Managed Finishing Services Wet Coating Powder Coating Silk Screening

 

After operating as a family-owned and operated business for 14 years, B & C became part of Pace Industries in 1998. Pace Industries B & C Division specializes in 100% zinc die casting serving the automotive, electronics, lighting and lawn and garden industries. In addition to zinc die casting, B&C provides a variety of additional capabilities to serve their wide-range of customers. Capabilities include single spindle drilling and tapping operations, CNC machining, dedicated multi-slide machining centers and component assembly. Along with conventional and multi-slide die casting capabilities, B&C boasts automated machines capable of producing flash free intricate castings in their TS 16949:2009 certified facility.

B&C Die Cast was founded in 1984 as a family-owned and operated business. They soon built a reputation and became one of the leaders in the industry with their quality product and service. In 1998, B&C joined the Pace family, specializing in 100% zinc die castings. B&C produces flash free intricate castings in their TS 16949 certified facility because of their conventional and multi-slide die casting skills.

Aside from die casting, B&C offers in-house machine and assembly experience to provide customers with options. Skills include: single spindle drilling and tapping operations, CNC machinery, multi-slide machine centers and component assembly. Below is a glimpse inside the factory’s day to day operations.

Bryan Heil
General Manager, JEL Finishing

From painting wheels for Henry Ford to painting computers for Digital Equipment to finishing castings for Pace Industries Cambridge Division, JEL Finishing, a company with over 85 years of experience, has become known as the “Finishing Specialist.”

JEL is known for its quality work and solutions in chromating, phosphating, wet painting, robotic electrostatic painting, silk screening, pad printing, stenciling as well as multiple automated powder coat systems. They are the authority on finishing aluminum parts, notably die castings.

In the 80’s, when the company was sold, the Nye’s name was dropped; JapEnameLac was shortened to JEL and completed to what there is today, JEL Finishing.

Industries Served

• Government
• Military and Defense
• Medical
• Aerospace
• Technology
• Steel and Aluminum Manufacturing
• Machine Shops
• Automotive Manufacturing
• Motorcycle Manufacturing
• Telecommunication
• Architectural Components
• General Industrial
• Marine
• Electrical components
• Casting Manufacturing
• Audio Manufacturing

Throughout the company’s history and all of the many projects, JEL is proud of every piece of work they put out. A few notable projects JEL has worked on is the powdering and painting of parts to support American troops during the Iraqi conflict several years ago. JEL was tasked by the Army to finish reactive armor for Abram Tanks and parts for the netting system that QinetiQ developed to stop RPGs from killing troops in their lightly armored vehicles. But, you might also notice some of JEL’s projects everyday – the white satellite tracking dome on the back of tractors going down the highway, JEL painted every one of them for Qualcomm.  When a helicopter flies overhead, if a Flir infrared camera is attached to it, JEL was responsible for painting it.  And not to drop names, but if you go to Fenway Park, you may see some tables and stools JEL powder coated for the Red Sox.

JEL Finishing’s most recent and outstanding accomplishments was being named one of the best finishing shops in North America, according to an industry benchmarking survey conducted by Products Finishing magazine, a trade publication which has covered the industry since 1938.

JEL’s quality, customer service and technical expertise make them stand apart from other job shop finishers.  The fact that they are integrated with in-house pretreatments such as blasting, chromating and zinc phosphating, can painting or powder coating small and large jobs, assembling hardware and also offer expert masking and printing services sets them apart from others. They are a solution provider offering a wide array of capabilities and services. They preach and practice safety first and respect and value every associate.  JEL’s associates are their best assets.

Pace Industries has many die-casting factories all over the country and even in Mexico. Our plant in Harrison, Ark. is known as a leader in thin wall and large mass castings for large volume customers in the lawn and garden, lighting and automotive industries. We have a variety of highly complex casting programs that require sophisticated automated robots to help streamline processes and a large work force to keep production moving.

Here’s a look into the new and improved Harrison plant, back on its feet after the fire that occurred in April of 2013 and the associates that are contributing to our success and that of our customers every day: