Casting Services
Casting Services
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Casting Services

Casting Technologies & Typical Products
We offer multiple casting processes to meet different requirements for quantity, complexity, accuracy, and cost.
Sand Casting

Process: A pattern is placed in sand to form a mold; molten metal is poured into the cavity. Suitable for large parts and low to medium volumes.

Typical products:

  - Machine tool beds and frames

  - Large pump bodies and valve bodies

  - Wind turbine hubs and main shafts

  - Construction machinery arms and counterweights

  - Marine propeller brackets

Advantages: Low tooling cost, accommodates very large parts (up to several tons), wide material choice.

Investment Casting (Lost‑Wax Casting)

Process: A wax pattern is coated with ceramic slurry to form a shell; wax is melted out, then molten metal is poured into the shell. Ideal for complex, near‑net‑shape parts.

Typical products:

  - Turbine blades and vanes (aerospace)

  - Impellers and rotors

  - Surgical instrument handles and orthopedic implant prototypes

  - Valve balls and stainless steel fittings

  - Complex brackets with internal passages

Advantages: Excellent surface finish (Ra 1.6–3.2μm), tight tolerances (±0.1mm), thin walls possible, minimal post‑machining.

Die Casting (High‑Pressure)

Process: Molten metal is injected into a steel mold (die) under high pressure. Suitable for high‑volume production of non‑ferrous alloys.

Typical products:

  - Automotive engine blocks, transmission housings, electric motor housings

  - Consumer electronics frames

  - LED heat sinks

Advantages: Fast cycle times, good surface finish, dimensional consistency.

Gravity / Low‑Pressure Die Casting

Process: Metal is poured or pressurized into a permanent mold under low pressure. Combines good mechanical properties with moderate tooling cost.

Typical products:

  - Automotive wheels

  - Cylinder heads

  - Structural suspension components

  - Battery trays for electric vehicles

Advantages: Lower porosity than high‑pressure die casting, suitable for heat‑treatable alloys.

Lost Foam Casting

Process: A foam pattern is embedded in sand; molten metal vaporizes the foam and fills the cavity. Good for complex, one‑piece castings.

Typical products:

  - Engine blocks with integrated internal passages

  - Complex valve bodies

  - Art/sculpture and industrial machinery components

Materials & Process Precision
Stainless Steel
Carbon & Alloy Steel
Aluminum Alloys
Copper‑based Alloys
Nickel / Cobalt Alloys
Titanium Alloys
Stainless Steel

Typical Grades: 304, 316L, 17‑4PH, CF8M

Key Properties & Applications: Corrosion resistance, high strength – valve bodies, marine parts, medical instruments, food equipment

Carbon & Alloy Steel

Typical Grades: 1020, 1045, 4140, 4340

 

Key Properties & Applications: High strength, wear resistance – machine frames, gear blanks, heavy equipment parts

Aluminum Alloys

Typical Grades: A356, A380, 6061 (cast equivalents)

Key Properties & Applications: Lightweight, good thermal conductivity – automotive wheels, pump housings, heat sinks

Copper‑based Alloys

Typical Grades: C83600 (bronze), C36000 (brass)

Key Properties & Applications: Wear resistance, corrosion resistance – bushings, valve seats, propellers

Nickel / Cobalt Alloys

Typical Grades: Inconel 718, Hastelloy, Stellite

Key Properties & Applications: Extreme heat and corrosion resistance – turbine blades, chemical processing components

Titanium Alloys

Typical Grades: Ti‑6Al‑4V (Grade 5)

Key Properties & Applications: High strength‑to‑weight ratio, biocompatible – aerospace structural parts, medical implants

Precision in the Casting Process

Parameter

Sand Casting

Investment Casting

Die Casting

Typical tolerance

±0.5 – 2.0mm

±0.1 – 0.3mm

±0.05 – 0.1mm

Surface roughness (Ra)

6.3 – 12.5μm

1.6 – 3.2μm

0.8 – 1.6μm

Minimum wall thickness

3 – 5mm

0.8 – 1.5mm

0.5 – 1.0mm

Maximum weight

> 10,000 kg

~50 kg

~10 kg (aluminum)

Key precision enablers
Simulation software (MAGMA, AnyCasting)
Predicts filling, solidification, and porosity; optimises gating/riser design before first pour.
CNC‑machined patterns / dies
Ensure accurate cavity dimensions.
Controlled solidification
Directional solidification techniques minimise shrinkage defects.
Heat treatment
Solution annealing, aging, and stress relieving to achieve specified mechanical properties and dimensional stability.
Quality Control – Meeting High Standards (Aerospace, Medical & Beyond)
We implement a comprehensive quality assurance system to ensure that cast parts meet the stringent requirements of aerospace, medical, and other critical industries.
In‑Process Quality Controls
Raw material
Spectrometer analysis for chemical composition; hardness test; material certificate traceable to heat number
Mold / die preparation
Dimensional check of patterns, dies, and core boxes; coating thickness verification
Melting & pouring
Temperature control (±10°C); degassing and fluxing for melt cleanliness
Post‑casting
Controlled cooling; fettling (gate/riser removal); shot blasting / grinding
Heat treatment
Furnace calibration; time‑temperature records; hardness verification
Non‑Destructive Testing (NDT) – Critical for Aerospace & Medical
Radiography (X‑ray)

Detects: Internal porosity, shrinkage, cracks

Typical Acceptance Standard: ASTM E94, ASTM E155 (for castings)

Ultrasonic testing

Detects: Subsurface voids, inclusions

Typical Acceptance Standard: ASTM A388, AMS 2630

Dye penetrant (PT)

Detects: Surface cracks, porosity

Typical Acceptance Standard: ASTM E165

Magnetic particle (MT)

Detects: Surface/near‑surface defects in ferrous castings

Typical Acceptance Standard: ASTM E1444

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Destructive Testing (Sample‑based)
Tensile testing
Yield strength, ultimate tensile strength, elongation (ASTM E8 / E8M)
Hardness testing
Brinell, Rockwell (per material specification)
Metallographic examination
Grain structure, phase distribution, inclusion rating
Impact testing
Charpy V‑notch (for low‑temperature applications)
Dimensional Inspection
Coordinate Measuring Machine (CMM)
For complex contours and critical features
Laser scanning / 3D white light scanning
Full surface comparison to CAD model
Custom gauges
For high‑volume production verification
Traceability & Documentation
Batch traceability

Each casting is marked with a unique ID (laser engraving, dot peen, or tag) linking to
- Material heat number
- Mold/die ID
- Production date and operator
- Heat treatment batch
- Inspection records (NDT, dimensional, mechanical)

Documentation package available:

  - Material certificate (EN 10204 3.1 or 3.2)
  - First Article Inspection Report (FAIR) per AS9102 (aerospace)
  - NDT reports with images
  - Mechanical test reports
  - CMM / scanning reports

Industries We Serve
Aerospace

Standard/ Requirement: AS9100, NADCAP, AMS specifications

Our Approach: Process control, NDT records, full traceability, customer source inspection

Medical

Standard/ Requirement: ISO 13485, FDA 21 CFR Part 820 

Our Approach: Biocompatible materials (ISO 10993), clean processing, validated cleaning, packaging

Automotive

Standard/ Requirement: IATF 16949, PPAP level 3

Our Approach: Process capability (CPK ≥1.33), control plans, FMEA

General Industrial

Standard/ Requirement: ISO 9001:2015

Our Approach: Standard quality management system

Why Choose Our Casting Services?
Multi‑process capability
Sand, investment, die, and gravity casting under one roof
Material expertise
Stainless steel, carbon/alloy steel, aluminum, copper‑based, nickel alloys, titanium
Precision
Investment casting delivers near‑net shapes with ±0.1mm tolerance; sand casting for large structural parts
Strict quality control
In‑house NDT (X‑ray, ultrasonic, PT, MT), CMM, and metallurgical lab
Certified
ISO 9001, AS9100 (aerospace), ISO 13485 (medical), IATF 16949 (automotive) as required
Integrated services
We can combine casting with CNC machining and surface finishing to deliver ready‑to‑use parts
OUR SERVICES
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We offer three main categories of sheet metal fabricated parts, ranging from protective enclosures to load‑bearing structures and welded assemblies.

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Casting Services
Casting Services

We offer multiple casting processes to meet different requirements for quantity, complexity, accuracy, and cost.

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