New Dedicated Manufacturing Cell for Diesel Engine Piston

Engineering & Build of Manufacturing Cell for Diesel Engine PistonDay Piston Company was commissioned by a diesel engine manufacturer to undertake the complete engineering, design, and fabrication of new dedicated manufacturing cell at Day Piston. The cell would be designed to produce cast iron pistons for their aftermarket customers. It would have to be able to manufacture pistons with a 4" outside diameter, 6" in length, weighing 5 lbs. while maintaining tolerances of ±.00045".

This project would utilize all of our diverse engineering and manufacturing capabilities. The manufacturing cell would include highly engineered tooling and work holding fixtures, all specially developed for this project. It would also include a vertical machining center, a CNC lathe, and special purpose presses.

Once the design was completed and qualified, we began the manufacturing process. Fabrication was completed primarily with our extensive CNC machining capabilities, which included CNC turning, milling, and grinding, as well as wide range of other necessary machining and fabricating processes.

Quality is of integral importance to us. To ensure the reliability and durability of the manufacturing cell, we performed pressure leak testing, magnetic particle inspection, and dimensional in process inspections. Our IATF16949 quality system was central to controlling all internal processes for the engineering and manufacturing of the piston.

Because of the diversity of our resources, and dedication to providing our clients with quality products and value added services, our customers view us as an extension of their manufacturing department. This view speaks to the long term partnership that we've developed with our customers, and our dedication to fulfilling their needs.

To learn more about this project, or about our other capabilities and services, see the table below or contact us directly.

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Highlights of this Custom Engineering & Fabrication Project

Manufacturing Cell Engineering Cast Iron piston used in large diesel engines.
Capabilities Applied/Processes
  • Designed Complete Manufacturing Cell to Produce Cast Iron Pistons
Tooling Design and Manufacturing
  • Highly Engineered Tooling and Work Holding Fixtures Developed for Manufacturing Cell
Equipment Used to Manufacture Part
CNC lathes, mills
Centerless grinders
Secondary operations:
  • Bushing presses
  • Drilling machines
*Machine tools are organized in production cells to maximize efficiency
*A local plating company specializing in piston plating was used for tin plating.
Components of Cell Vertical Machining Centers
CNC Lathes
Special Purpose Presses
Overall Part Dimensions 4" O.D. X 6" length
Tightest Tolerances < .001
Material Used Cast Iron
Material Finish 45 micro finish
In process testing/inspection performed Pressure leak testing
Magnetic particle inspection
Dimensional in process inspection
Estimated Part Weight 5 lbs
Industry for Use Diesel Engines
Delivery Location Michigan
Standards Met Magnetic Particle Inspection
Pressure leak testing
TS 16949 quality system
Product Name Piston

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