Metal Casting Services

Create complex, robust metal parts for prototypes and production runs. Our casting services offer a versatile and cost-effective method for producing near-net-shape components in a huge range of alloys.

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A complex metal impeller, an application where investment casting is often used

The Original Manufacturing Process

Casting is a manufacturing process where a liquid material, typically molten metal, is poured into a mold containing a hollow cavity of the desired shape. The liquid then cools and solidifies, and the resulting part (the casting) is ejected or broken out of the mold. It is a highly versatile process capable of producing intricate shapes that would be difficult or impossible to make with other methods.

Investment Casting (Lost-Wax)

This process uses a wax pattern of the final part, which is coated in a ceramic slurry to create a shell mold. The wax is then melted out, and molten metal is poured into the ceramic cavity. Investment casting produces parts with excellent dimensional accuracy and a very smooth surface finish. It's ideal for complex, high-detail parts.

Sand Casting

In this process, a pattern of the final part is pressed into a special mixture of sand and a binding agent to create the two halves of a mold. It is a very low-cost process, ideal for producing very large parts or for low-volume prototypes where tooling cost is a primary concern. The parts have a rough surface finish and less dimensional accuracy.

Why Choose Metal Casting?

Geometric Complexity: Casting allows for the creation of intricate internal and external features, offering a high degree of design freedom.
Wide Material Selection: Almost any metal or alloy can be cast, from aluminum and zinc to stainless steel, bronze, and high-strength steel alloys.
Near-Net-Shape Parts: The casting process produces parts that are very close to their final dimensions, reducing the amount of secondary machining required and saving material.
Scalability: The same design can be produced with low-cost sand casting for prototypes and then transitioned to investment casting or die casting for higher volumes.

A complex stainless steel part, showcasing the geometric freedom of casting

Metal Casting FAQ

How does casting compare to die casting?

Die casting is a specific type of casting that uses a reusable steel die and injects metal under high pressure. It's very fast and suitable for high volumes. General casting processes like sand casting and investment casting use expendable (single-use) molds made of sand or ceramic. These processes are slower but have much lower tooling costs and can be used for a wider range of alloys, including ferrous metals like steel.

What kind of tolerances can casting achieve?

Tolerances vary by process. Sand casting has the loosest tolerances. Investment casting offers much better accuracy, often approaching that of die casting. However, for any critical features that require very tight tolerances, a secondary CNC machining operation is typically performed on the cast part.

What is a "pattern" in casting?

The pattern is the master shape used to create the mold cavity. For sand casting, it's a reusable model of the part (often made from wood or plastic). For investment casting, it is a disposable pattern made of wax. We can use 3D printing to rapidly create high-detail patterns for both processes.