EN
- Overview
- Related Products
I. Core Service Advantages
- Seamless integration throughout the entire process, shortening product launch cycles: We provide a comprehensive service chain from prototyping to rapid casting, performance testing, pilot testing, and adjustment to mass production. During the prototype stage, we utilize 3D-printed wax and silicone molds for rapid casting, delivering samples within 7-10 days. During the pilot stage, we simultaneously optimize process parameters and mold structure. During the mass production phase, we switch to standardized production lines, achieving a seamless transition from prototyping to mass production, shortening the overall cycle time by 30%-40% compared to traditional methods.
- Precise adaptation of multiple materials to meet diverse operating requirements: We support the casting of a variety of materials, including stainless steel (304/316L), alloy steel (4140/4340), titanium alloy (TC4/GR5), aluminum alloy (A356/A6061), and high-temperature alloys (Inconel 718/Hastelloy C276). We can recommend the optimal material based on product requirements (e.g., high-temperature resistance, corrosion resistance, and high strength). Our casting material composition qualification rate exceeds 99.5%.
- Precision shape control and performance assurance to meet high-end demands: Utilizing processes such as investment casting and sand casting, castings achieve dimensional accuracy of CT4-CT7 (according to ISO 8062), surface roughness Ra ≤ 1.6μm, and key geometric tolerances (such as coaxiality and flatness) within ±0.02-±0.05mm. Heat treatment (tempering, solution aging) and non-destructive testing (X-ray inspection, penetrant testing) ensure that mechanical properties such as tensile strength and elongation meet standards, while keeping scrap rates below 2%.
- Flexible production capacity and cost optimization to accommodate varying scale requirements: Prototype production supports small-batch trial runs (1-50 pieces), while mass production can reach annual production capacity exceeding 1 million pieces. Equipped with multiple standardized casting lines and automated cleaning equipment, larger batches lead to significant unit cost advantages. Process simulation optimizes casting structure (e.g., reducing gating and riser sizes and optimizing wall thickness distribution), reduces material loss (≤5%), and further controls production costs.
II. Core Application Areas
(I) Aerospace
- Engine and fuselage components: Investment casting of high-temperature alloy (Inconel 718) engine blades, titanium alloy (TC4) fuselage frame joints, with a temperature resistance of up to 650-800℃ and a tensile strength of ≥900MPa, meeting the extreme working conditions of aerospace; precision casting of stainless steel (316L) avionics equipment housings, waterproof and corrosion-resistant, with dimensional accuracy of CT5 level.
(II) Automobile and New Energy Fields
- Power system parts: Sand mold precision casting of aluminum alloy (A356) turbocharger housings, alloy steel (4140) crankshafts, with a casting density of ≥99.8%, reducing power loss; casting of stainless steel (304) new energy vehicle battery brackets, with a lightweight design (30% lighter than steel) and excellent impact resistance.
(III) Energy and Industrial Equipment Field
- Energy Equipment Components: Cast nickel-based alloy (Hastelloy C276) chemical reactor impeller, with strong corrosion resistance and adaptability to acid and alkali media; investment casting stainless steel (316L) wind turbine flange, with dimensional accuracy of CT6, ensuring precise connection with the tower.
- Industrial Machinery Parts: Precision casting alloy steel (4340) gearbox housing, aluminum alloy (A6061) machine tool guide slider, the casting surface can be assembled without secondary processing, improving equipment
production efficiency.
(IV) Medical and High-end Equipment Field
- Medical Equipment Parts: Investment casting titanium alloy (GR5) artificial joints, stainless steel (316L) surgical instrument housing, with good biocompatibility and surface roughness Ra≤0.8μm, meeting medical-grade hygiene standards.
- High-end Instrument Components: Cast aluminum alloy (ADC12) precision instrument base, stainless steel (304) sensor housing, with dimensional accuracy of CT5, ensuring stable instrument detection accuracy.
III. Core Technology Support
- Full-Process Design and Simulation: 3D modeling of castings is performed using UG and Pro/E. MAGMASOFT casting simulation software is used to simulate the filling and solidification processes, predicting defects such as shrinkage cavities and cracks. This allows for pre-optimization of the gating and riser system and process parameters, resulting in a first-pass yield of over 98%.
- Multi-Dimensional Precision Casting Processes:
- Investment Casting: Suitable for complex, thin-walled parts (minimum wall thickness 0.8mm) and high-precision parts (CT4-CT6 grade), such as aircraft engine blades and medical joints;
- Sand Precision Casting: Utilizing resin sand molding, it is suitable for medium-to-large castings (maximum weight 500kg) and mass-produced parts, such as automotive turbine casings and wind turbine flanges;
- Rapid Casting: Combining 3D printed wax and sand mold technology, prototypes can be delivered as quickly as 7-10 days, eliminating the need for mold creation and reducing R&D costs. - Strict Quality Inspection System:
- Material Testing: Spectrometers verify composition, tensile testing machines and hardness testers test mechanical properties;
- Nondestructive Testing: X-ray (RT), ultrasonic testing (UT), and penetrant testing (PT) ensure internal defects;
- Dimensional Inspection: Coordinate Measuring Machines (accuracy ±0.001mm) and blue light scanners perform full-dimensional inspections in compliance with ISO 8062 standards.
- Digital Production Management: An MES system is introduced to ensure full process traceability from order to delivery, with real-time monitoring of key parameters such as casting temperature and pressure. Automated cleaning lines (shot blasting and polishing) and robotic sorting are also equipped to improve mass production efficiency and product consistency.
IV.Frequently Asked Questions (FAQs)
- Q: What is the lead time for precision casting prototypes? What design information is required?
A: Prototype delivery time is 7-10 days. A 2D engineering drawing (with tolerances marked) or a 3D model (STEP/IGS format) is required. If you have special performance requirements (such as high-temperature resistance or corrosion resistance), please specify them simultaneously. We will recommend suitable materials and processes.
- Q: What are the differences in the application scenarios of different casting processes? How do I choose?
A: Investment casting is suitable for complex, high-precision small parts (such as blades and joints); sand casting is suitable for medium-to-large, mass-produced parts (such as turbine casings and flanges); and rapid casting is suitable for R&D prototypes or small-batch trial production. Our process team can recommend the optimal solution based on part size, complexity, batch size, and precision requirements.
- Q: What dimensional accuracy and surface roughness can be achieved for castings? Is secondary machining required?
A: Dimensional accuracy can reach CT4-CT7 levels, with a surface roughness of Ra ≤ 1.6μm. For critical surfaces with extremely high precision requirements (such as mating surfaces), we provide subsequent CNC finishing services to ensure they meet assembly requirements. Non-mating surfaces generally do not require secondary machining and can be used directly. - Q: What is the minimum order quantity for mass production? Can our production capacity accommodate urgent orders?
A: There is no strict minimum order quantity for mass production, and we support orders ranging from 100 to 1 million pieces. Our annual production capacity exceeds 1 million pieces, and we have three casting lines operating in parallel. We can adjust our production capacity to meet urgent orders, allowing for expedited delivery within 15-20 days (depending on order volume).
- Q: Can you provide quality reports and compliance certificates for castings?
A: Yes! Each batch will be accompanied by material inspection reports, non-destructive testing reports, and dimensional inspection reports. For aerospace, medical, and other fields, we can provide industry compliance certificates such as AS9100 and ISO 13485 to ensure our products meet customer industry standards.
