Metal Casting

Metal casting with the highest craftsmanship

Our expertise expands beyond CNC machining and Metal Profiling. As a Full-Service manufacturing solution provider, we are also experts in Casting Manufacturing. We are among the first to pioneer the offshore casting manufacturing approach, bringing a variety of casting solutions to global customers at a highly competitive price.

High Quality | Omnidex Laser
Filling mold cavity with molten metal
Aluminium Gravity Casting Services | High Quality | Omnidex Laser | Omnidex Castings
Aluminium Gravity Casting
Metal Sand Casting Services | High Quality | Omnidex Laser | Omnidex Castings
Sand Casting Services

Versatile solutions with unlimited casting manufacturing capacity

With over 18 years in the manufacturing business, we have developed a close connection with many sub-contractors in Asian industrial hubs. Combining the manufacturing capabilities of these specialized factories and our in-house engineering, we can provide a wide range of quality Metal Casting solutions, including Sand Casting, Permanent Mold Gravity Casting, Die Casting, Investment Casting, Lost Foam Casting and Shell Mold Casting. Find out more about our Casting Manufacturing solutions below.

Sand Casting is a casting process that uses a sand mold for casting. It is a relatively affordable and versatile process that can handle a wide range of casting sizes and shapes. Over 60% of all metal castings are produced via this approach. 

Pros and Cons of Sand Casting

Relatively inexpensive tooling
• Can produce very large parts (from 1 kg all the way up to 15 MT)
Can be used to cast a variety of materials, including special steels, grey iron or ductile iron, as well as non-ferrous metals
Can handle a diverse range of shapes and design

Usually limited to one casting piece per mold box
High level of sand and scrap waste. (This can be reduced if the waste is reclaimed and treated properly)
Labour intensive operation
More prone to shrinkage and porosity issues

Sand Casting

Aluminium Bracket

Sand Casting

Aluminium Bracket

Sand Casting

Steel Sand Casting

Sand Casting

Cast Iron Grill

Sand Casting

Cast Iron Automotive Bracket

Sand Casting

Machined Steel Casting

Permanent Mold Gravity Casting uses “permanent molds” that can be reused many times, and the pouring process involves only the force of gravity (without the use of pressurized gases, vacuums, or centrifugal force).

Pros and Cons of Permanent Mold Gravity Approach

Reusable molds
Higher precision and accuracy 
Can produce more complex and detailed castings 
Excellent as-cast surface finish 
• Good mechanical properties
• Highly repeatable and well-suited for high volume production runs

 

More suitable for materials with lower melting temperatures (aluminium, magnesium, tin, zinc, copper and lead alloys)
Defects may occur due to mold wear down
Casting geometry and size limited by mold making
Higher tooling cost and longer set-up time
• Too expensive for small volume production runs

permanent mold gravity casting

Aluminium Automotive Manifolds

permanent mold gravity casting

Aluminium Automotive Manifolds

permanent mold gravity casting

Aluminium Automotive Manifolds

permanent mold gravity casting

Aluminium Automotive Manifolds

permanent mold gravity casting

Aluminium Automotive Manifolds

permanent mold gravity casting

Aluminium Automotive Manifolds

Looking for the Best Manufacturing Solution for your Project?
The Die Casting process is characterized by forcing molten metal under high pressure into a mold cavity. There are basically 3 types of die casting: Hot-chamber, Cold chamber and Multi-Slide Hot-Chamber Die Casting.

Pros and Cons of Die Casting

Very cost-effective for high volume production runs
Excellent dimensional accuracy and consistency
Can reach a very high production rate
• Smooth as-cast surfaces
• Reduced need for additional machining

Higher initial tooling costs
Limited to non-ferrous metals (aluminium, magnesium, zinc, brass and copper alloys)
Part size limited by the die casting machine

Die casting manufacturing

Magnesium Die Cast Camera Housing

Die casting manufacturing

Die Cast Automotive Part

Die casting manufacturing

Die Cast Automotive Bracket

Metal Casting

Magnesium Die Cast Camera Housing

Die casting manufacturing

Magnesium Die Cast Camera Housing

Die casting manufacturing

Magnesium Die Cast Camera Housing

Investment casting method uses specialized waxes to make wax patterns, which are then used to make the ceramic shell molds. This approach is able to create intricate forms, make undercuts, eliminate parting lines and produce castings with extremely tight dimensional tolerances, but the molding process also takes more time.

Pros and Cons of Investment Casting

Offers many metal and alloy options (copper, magnesium, aluminium, ductile iron, carbon steel, stainless steel, tool steel, titanium and many other alloys)
Higher precision and accuracy 
More freedom in casting design
• Relatively low tooling cost
• High dimensional accuracy with tight tolerances
• Excellent as-cast surface finish with no parting lines
• Reduced additional machining

Longer production cycle
Higher manufacturing cost (due to die making, specialised equipment, refractory material, and labour)
Not recommended for parts with holes smaller than 1⁄16 of an inch (1.6 mm) or deeper than 1.5 times the diameter
Not viable for small production runs

Investment casting

Investment Casting: Valve

investment casting

Scientific housing

investment casting

Scientific housing

investment casting

Scientific housing

investment casting

Compressed Air Filter Cap

investment casting

Investment Casting: Valve

Lost Foam Casting is characterized by the use of polystyrene foam patterns to form the mold. The foam is later vaporized by the molten metal pouring into the molds.

Pros and Cons of Lost Foam Approach

Able to produce large and complex castings in one piece
No need to use additional cores for hollow parts
• High dimensional accuracy
• Excellent as-cast surface finish
• No draft required
• No parting lines, no flash is formed
• Reduced machining and cleaning

Relatively higher manufacturing cost (due to specialised equipment, tooling, and labour)
Costs for pattern production can be high for low volume production
• Foam patterns can be easily damaged or distorted

Lost foam casting

Lost Foam Slurry Pump Housing

Lost foam casting

Lost Foam Cast Bracket

Lost foam casting

Lost Foam Cast Pump Pedestal

Shell Mold Casting is quite similar to sand casting. The process often involves specialized Shell Molding machines. A metal pattern is heated up in the machine before fine-grained, high-purity sand mixed with a thermosetting resin is added to form a temporary shell mold. This process offers superior dimensional accuracy across a wide range of ferrous and non-ferrous alloys (alloy steel, stainless steel, carbon steel, cast iron, aluminum alloys, copper alloys, nickel alloys).

Pros and Cons of Shell Mold Casting

Excellent dimensional accuracy (greater accuracy can be achieved using zircon sand)
• Good surface finish
• Can use a wide range of ferrous or non-ferrous metals
• Shorter project lead times
• Can be automated for large-scale production

The sand resin used in shell casting is expensive and cannot be reclaimed
Higher equipment cost
• Product size limited by Shell Molding machines

Choose the right project route and casting process for your product

There are many factors to consider when it comes to choosing manufacturing processes. We highly recommend exploring all the options with our engineers before making your final decision. Contact us here for more information about different casting process approaches or discuss your project requirements in more detail.

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Omnidex Group

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Manufacturing Processes

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480+

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Omnidex Castings offers and specialises various metal casting processes, to find out more about our Castings Team and how we can help you, please click HERE for more Information.

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