Metal Casting

Large Size, Complex Shapes, Mass Production

Why Metal Casting?

High Possibility

The size, thickness, and shape of castings are essentially unrestricted in the metal casting process; casting wall thicknesses range from 0.3 to 1000 mm, lengths range from a few millimeters to ten meters, and quality ranges from a few grams to more than 300t. For the production of parts with complex shapes, especially those with complex cavities, such as complex boxes, valves, impellers, engine cylinders, propellers, etc., the metal casting process is best.

Wide Range Of Materials Choices

There are numerous materials available for metal castings. For casting, almost any material can be melted into a liquid alloy, including steel, various aluminum alloys, copper alloys, iron alloys, castings made from platinum alloys, and so on. Casting is the only practical forming method for brittle alloy materials with low plasticity, such as regular cast iron. Cast iron is the most commonly used material in industrial production, accounting for more than 70% of total output.

Least Cost Process For Mass Production

Casting performs more economically overall and uses less energy and materials than other metal forming techniques. Its low cost can be attributed to three factors. To begin with, the production processes are adaptable; mass production can be set up as mechanized production. Second, recyclable materials, waste, and old metal can all be used. Last but not least, casting has a certain degree of dimensional accuracy, the allowance is small, and it conserves metal materials and processing time.

Free Consultation and Instant Quote

Send us your CAD file or 2D draft, with product requirements to get an instant quote.

Quick Production

With our GBA approved manufacturers, you can receive parts in as less as 3 days in Eastern South region.

Service with No Worries

We will keep reporting to you the production and shipping status once we get started.

Casting | Stainless Steel | Welding | SandBlasting

Process of Metal Casting

Examine The Raw Material

As a metal casting facility, we are accountable for quality, starting with the raw materials used. That is why we always examine the raw material at the beginning to make sure that adheres to our strict standards for quality.

Create The Mold And Coremaking

The molten metal must first be contained and shaped in a mold cavity in order to successfully produce a casting. In many instances, we also need to create a core that will fit inside the mold and leave hollow spaces inside the finished part. Molds and cores may be single-use for greensand casting or shell mold casting, or they may be reusable for die casting or permanent molding.

Melting And Pouring

Our melting process by heating the alloy over a burner or open flame and placing it in a receptacle with a higher melting point. We must pour the molten metal into the mold cavity after melting the alloy. The pouring process is supported by a ladle system, which enables operators to manually or automatically control pouring speed. When pouring is done incorrectly, gases can get trapped inside the mold and cause holes to form in the finished casting.

casting melting pouring
Solidify

Once more, manufacturers must take into account the molten metal’s shrinkage during cooling and the release of gases that accumulate inside the mold during pouring. To guarantee that they satisfy the required hardness, castings go through a variety of heating and cooling procedures, mechanical and metallographic requirements.

Cleaning, Heat Treatment And Inspection

The majority of cast parts need to be finished with processes like cleaning (the removal of extra material from the part), gate removal (the removal of the pouring channels from the part), heat treatment (the heating and cooling of the castings in a controlled environment to improve physical properties), and inspection for the castings’ specs and quality control.

Additional Machining And Surface Finishes

Castings can be processed using CNC machining centers and other equipment, to fulfil the requirements of the product. To improve the corrosion protection and aesthetic appeal of castings, the surface might need to be given various treatments like phosphate treatment and spray painting.

Materials for Metal Casting

We cover a wide range of major metals for 3D Printing, CNC machining, Casting and Sheet Metal Fabrication, with applications in multiple industries. This enanbles customers to achieve both one-off prototypes and end-use custom parts.

3D Print_Aluminium

Aluminum

✔ Low weight
✔ Fast Building
✔ High strength and hardness

Stainless Steel

✔ Can apply to Food Processing
✔ Easily machined into diverse shapes
✔ Excellent strength, corrosion resistant

3d printing | copper

Copper Alloy

✔ Strong alloy with corrosion resistance
✔ Unlike iron, neither brass nor bronze rusts
✔ Jewelry size to large sculptures

3D Print_Titanium

Titanium Alloy

✔ Lightweight & Bio-compatible
✔ Sports, Medical & Aerospace use
✔ Excellent resistance to cavitation

maraging steel_3d printing

Maraging Steel

✔ Ideal Tool Steel for mold designs
✔ Easily fabricated into gears & mandrels
✔ High ductility, strength & wear resistance

Surface Finish Selection

You may pick from a variety of secondary operations that create final production parts, such as heat treating, tapping, reaming, and post-process machining.

post processing | surface finishes | electroplating

Electroplating

Aesthetic improvement
✔ Temperature resistance
✔ Increase corrosion resistance

Painting

✔ Aesthetic improvement
✔ Increase corrosion resistance
✔ Increase abrasion resistance

CNC | Aluminum | post processing | surface finish | Anodizing

Anodizing

✔ Aesthetic improvement
✔ Increase corrosion resistance
✔ Increase wear resistance

aluminium | sandblasting

Sandblasting

✔ Smoother
✔ Reduce flaws
✔ Remove old paint
post processing | surface finish | polishing

Polishing

✔ Aesthetic improvement
✔ Increase corrosion resistance
✔ Increase chemical resistance
Brushed stainless steel metallic surface

Brushing

✔ Smoother
✔ Deburring
✔ Edge rounding

Standard:  Sand surfaces to remove build lines and bead blasted.

Anodized:  Electrochemical process that converts the metal surface into a decorative, durable, corrosion-resistant, anodic oxide finish

Heat Treated:  Use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of a material

Polished: Sand surfaces to remove build lines and then apply polishing compound until desired surface finish is reached.

Metal Plated: Aluminum can be plated with a wide range of metals to increase its corrosion resistance, increase wear resistance, or improve overall aesthetics. Both electroplating and electroless plating are possible. Some common metals include tin, nickel, electroless nickel, gold, and silver.

Powder Coating: Powder coating is a robust option for coloring aluminum sheet metal parts while also adding a measure of corrosion resistance.

Additional post-processing: Includes CNC milling, lathing & EDM

Other Manufacturing Services

To know more, contact us for a free consultation and instant quote.