01
Tooling Design & Development
Our engineering team develops precision tooling using advanced Design for Manufacturing (DFM) principles, ensuring optimal casting quality, dimensional accuracy, and cost-effective production.
Foundry Excellence
Our Lost-Wax Investment Casting Process
A validated 15-step manufacturing process designed to deliver extraordinary dimensional accuracy and excellent surface quality for critical applications.
Integrated Production Workflow
A proven 15-step manufacturing process delivering dimensional accuracy and surface quality for critical applications.
02
Wax Pattern Injection
High-precision wax patterns are injected into reusable dies to create exact replicas of the final component, ensuring consistent dimensions and repeatability.
03
Pattern Assembly
Individual wax patterns are assembled onto a central runner system to form a casting tree, maximizing production efficiency and metal yield.
04
Ceramic Shell Building
Multiple ceramic coating and sand stucco layers are applied to create a robust, heat-resistant shell capable of withstanding molten metal temperatures while preserving intricate details.
05
Dewaxing
The ceramic shell is heated to remove the wax pattern, leaving behind a precise cavity that accurately replicates the desired component geometry.
06
Shell Firing
Ceramic shells are preheated to high temperatures to eliminate residual moisture, enhance metal flow, and minimize casting defects during pouring.
07
Metal Melting & Pouring
Selected alloys are melted under carefully controlled conditions and poured into the preheated ceramic moulds to produce high-integrity castings with superior metallurgical properties.
08
Cooling & Solidification
Carefully controlled cooling ensures uniform solidification, enhanced material integrity, and reduced internal stresses.
09
Shell Removal (Knockout)
After solidification, the ceramic shell is carefully removed to reveal the cast component while preserving its dimensional accuracy and surface finish.
10
Cut-Off & Fettling
Casting gates, runners, and excess material are removed, followed by grinding, blasting, and surface finishing to achieve the required surface quality and prepare the component for further processing.
11
Heat Treatment
Controlled heat treatment enhances the mechanical properties of the casting, improving strength, hardness, toughness, and overall performance based on application requirements.
12
CNC Machining (If Required)
Advanced CNC machining delivers tight tolerances, precision features, and superior surface finishes to meet exact customer specifications.
13
Surface Finishing
Finishing processes deliver the desired surface quality, dimensional precision, and corrosion-resistant appearance.
14
Inspection & Testing
Every casting undergoes rigorous quality inspection to ensure compliance with customer specifications before secure dispatch.
15
Packaging & Dispatch
Every casting undergoes rigorous dimensional, visual, and quality inspections before secure packaging and on-time dispatch, ensuring components are delivered ready for immediate use.
Extraordinary Casting Techniques
Advancements which allow us to achieve geometries impossible with standard casting methods.
Water Sol Core Technology
Enables the production of intricate internal passages and hollow geometries that are impossible with conventional cores, reducing machining, minimizing material waste, and delivering exceptional dimensional accuracy.
Shell-build line using quick-set gel slurry on wax assemblies400×220
Quick Set Gel Process
Enables the production of intricate internal passages with lower than 10mm diameter and hollow geometries that are impossible with conventional investment casting process, reducing machining, minimizing material waste, and delivering exceptional dimensional accuracy.
Ceramic Core Integration
Facilitates the casting of highly complex internal cavities, making it ideal for closed impellers, defence, EGR valves and other high-performance engineering applications.
Technical Specifications
| Parameter | Value |
|---|---|
| Weight Range | 20 Grams to 50 Kgs |
| Dimensional Tolerance | As Cast: As per IS 11166/VDG P690, Machining: Less than 20 Microns |
| Surface Finish | As Cast - Max 3.2 Ra, Machining - 0.4 Ra |
Frequently Asked Questions
Answers to the questions engineers and procurement teams ask most often before issuing an RFQ.
What materials can you cast?
We specialise in various range of ferrous and non-ferrous alloys, including stainless steel 300 and 400 series, carbon and low alloy steels, tool steels, cobalt alloys and nickel-base superalloys.
What tolerance do you achieve?
The dimensional tolerance is ±0.01mm to ±0.02mm for critical machined components, depending on geometry and material.
What is your weight and size range?
Castings from 10 grams to 50 kilograms, within a 600 × 600 × 600 mm envelope.
What is the particular lead time for new tooling?
The tooling development cycle runs between 6 and 10 weeks, depending on the complexity of the part, process, material and the level of dimensional accuracy.
What is your minimum order quantity?
150 kg per part, per release. We are happy to discuss smaller MOQs for first-time tooling proof-outs.
What surface finish do you achieve?
1.6 to 6.3 Ra as-cast; finer values after secondary machining.
What CAD file formats do you accept?
STP, STEP, IGS, IGES, SLDPRT, X_T, DWG and DXF — submitted via our RFQ form.
Do you support PPAP and FMEA?
Yes. All production automotive parts go through PPAP at the customer-required level, with full FMEA documentation.
Are uploaded drawings confidential?
Yes. All drawings are treated as confidential and are only shared with our engineering team. We sign customer NDAs on request.
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Our team of technical professionals are ready to assist you with your next intricate project. Check the detailed quote within 24 hours.