Our expertise expands beyond CNC machining and Metal Profiling. As a Full-Service manufacturing solution provider, we are also experts in Metal Casting. We are among the first to pioneer the offshore manufacturing approach, bringing a variety of Metal Casting solutions to global customers at a highly competitive price.
With over 17 years in the manufacturing business, we have developed close connection with many sub-contractors in Asian industrial hubs. Combining the manufacturing capabilities of these specialized factories and our in-house engineering, we are able to provide a wide range of quality Metal Casting solutions, include Sand Casting, Permanent Mold Gravity Casting, Die Casting, Investment Casting, Lost Foam Casting and Shell Mold Casting. Find out more about our Metal Casting solutions below.
Sand Casting is a process that uses sand mold for casting. It is a relatively affordable and versatile process that can handle a wide range of casting sizes and shapes. It is estimated over 60% of all metal castings are produced via 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
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).
• Reusable molds
• Higher precision and accuracy (compare to sand casting)
• Can produce more complex and detailed castings (compare to sand casting)
• Excellent as-cast surface finish (compare to sand casting)
• Castings have 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
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
• 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
This casting method uses specialized waxes to make wax patterns, which are then used to make the ceramic shell molds. Investment Casting 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.
• 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 (compare to sand casting)
• 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
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.
• 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
Shell Mold Casting is a process 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 for casting. 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).
• 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
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.
If you are interested in our Metal Casting solutions, feel free to contact us for more details.