Sand casting,investment casting,die casting Services

Custom casting manufacturing services
 

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What is casting?

Casting is mainly the method of pouring liquid metal into the mold cavity suitable for the shape of the part, and then obtaining the blank or part with a certain shape, size and performance after cooling and solidifying. The process is like using a special mold to shape metal. According to product accuracy and surface finish can be divided into ordinary casting and precision casting, ordinary casting is sand casting, precision casting is divided into investment casting, gravity casting and die casting. Each process can do single cavity mold or multi-cavity mold, almost every process can cast iron, stainless steel, copper, according to the product structure, the product accuracy requirements to choose the appropriate processing method.

Sand casting

Sand casting

Sand casting frame is generally wood mold. The inner cavity needs to make a pattern, the pattern is placed in the sand box, and then filled with molding sand, through the way of compacting the molding sand around the mold to form the mold cavity, when the pattern is removed from the sand, it leaves a cavity with the same shape as the casting. The molten metal is then poured into the cavity, where it cools and solidifies to form the casting. Due to the presence of sand particles, the traces of sand particles will be left on the surface of the casting, so the surface finish and dimensional accuracy of the product are low. The production equipment is simple, the cost is low, and it is often used for castings with uncomplicated shapes. If there are requirements for surface quality, the surface will be machined with CNC machining.

Learn more about sand casting

investment casting1

Investment casting

Investment casting is also called lost wax casting. The mold for making wax is a metal mold, which can be cast iron, cast steel or aluminum alloy. After the wax material is made into a pattern, multiple layers of refractory material are coated on the pattern, and after it is hardened, the wax mold is heated to melt out, forming a hollow shell, and then pouring metal molding. This mold is suitable for the production of complex shapes and high precision castings, such as engine blades in the aerospace field, artificial joints in the medical equipment field.

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Die casting

Die casting

Die casting is a casting method in which liquid or semi-liquid metal is quickly injected into the die cavity under high pressure and solidified under pressure. Die casting molds are usually made of high strength die steel H13 Liquid metal material can be aluminum alloy, zinc alloy, etc., liquid metal under high pressure can quickly fill complex mold cavity, so die casting can produce complex shape, thin-walled parts, die casting cycle time is short, suitable for mass production. Such as some parts of the automobile engine, the shell and internal structural parts of electronic products.

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Gravity casting

Gravity casting

Gravity casting mainly relies on the action of gravity to pour liquid metal into the mold cavity, in the absence of external force (such as pressure), let the metal liquid naturally fill the cavity, and then cool and solidify to form the casting. This casting method makes full use of the gravity of the liquid metal itself, just like water flowing downwards, the metal liquid enters the cavity from the gate and gradually fills the entire cavity space. Mold material according to the metal liquid to be cast to choose cast iron, steel, aluminum alloy, etc., if the product has a hollow inner cavity structure, with sand core, the product is molded after the sand core is knocked out. The dimensional accuracy and surface finish of gravity casting is not as good as that of die casting, but it is suitable for large and complex shapes of castings.

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Casting Parts from Mastersdex

Sand Casting Materials

Name

Description

Price

Aluminum

Light weight, corrosion resistance, good thermal conductivity, good electrical conductivity, easy processing

Brass

Corrosion resistance, high strength, good toughness, not as easy to work as mild carbon steel

Iron

High strength, light weight, corrosion resistance, high temperature resistance, not easy to milling

Investment Casting Materials

Aluminum

Corrosion resistance, high ductility, easy processing, excellent electrical and thermal conductivity, high density and weight

Brass

The strength is higher than stainless steel and more difficult to process, good toughness, wear resistance, corrosion resistance, good thermal stability.

Stainless steel

High hardness, strong wear resistance, good toughness, good corrosion resistance, good thermal stability. More difficult to mill.

Die Casting Materials

Name

Description

Price

die casting_aluminum alloy

Aluminum alloy

Tough and hard, impact resistant, easy to process, used for home appliance shell, automobile shell.

Die casting zinc alloy

Zinc alloy

High strength, good insulation, high temperature resistance, hard and brittle quality, used for insulation requirements of mechanical parts

Gravity casting Materials

Gravity casting aluminum

Aluminum

High transparency, impact resistance, heat resistance, good toughness; Used for optical lenses and electronic and electrical enclosures

Gravity casting brass

Brass

High temperature resistance, corrosion resistance, high strength, wear resistance, insulation; Used in aerospace and automotive demanding parts

Gravity casting iron

Iron

High transparency, toughness, chemical resistance, often used in packaging materials

Casting Parts Tolerance



Standards                                                                                           
 CNC turning milling combination/CNC milling                                                            
                                          CNC Turning
Maximum Part Size3000×1200×600 mm                             200×500 mm
Minimum Part Size2×2 mm                              2×2 mm
Minimum Feature SizeΦ 0.50 mm                              Φ 0.50 mm
Standard TolerancesMetals:DIN ISO 2768                             Metals: DIN ISO 2768

Plastics:DIN ISO 2768

 

                             Plastics:DIN ISO 2768

Linear Dimension+/- 0.025 mm                               +/- 0.025 mm
Hole Diameters(Not Reamed)+/- 0.025 mm                               +/- 0.025 mm
Shaft Diameters+/- 0.025 mm                               +/- 0.025 mm
Edge ConditionSharp corner will be removed in the form of a chamfer or radius. The size of the chamfer, or resulting radii, must be indicated on the drawing.
Threads and Tapped HolesDiameter: Φ 1.5-5 mm, depth: 3×diameter                         Diameter: Φ 1.5-5 mm, depth: 3×diameter
Diameter: Φ 5 mm or more, depth: 4-6×diameter                         Diameter: Φ 5 mm or more, depth: 4-6×diameter
Mastersdex can produce threads of any specification and size required by our customers.
TextUse CNC engraving or laser carving to create standard text based on customers’ requirements. Minimum width of 0.5mm, depth of 0.1mm. Use laser marking to create standard text for CNC turned parts.
Lead Time3 to 10 business days 3 to 10 business days

Casting surface treatment

Name

Description

Price

Gravity casting aluminum

Nature

Retain the natural texture of processing,usually,it mean Ra 1.6 or Ra3.2 for the metals,R3.2 for the plastics.

casting+CNC machining

Nature+CNC machining

Retain the natural texture of processing,usually,it mean Ra 1.6 or Ra3.2 for the metals,R3.2 for the plastics.

casting_polishing-re

Polishing

Retain the natural texture of processing,usually,it mean Ra 1.6 or Ra3.2 for the metals,R3.2 for the plastics.

Sand_blast-re

Sand blast

It can cover the processing texture, clean and decontaminate, strengthen the surface hardness, more wear-resistant

Sand blast with anodizing

Sand blast+Anodizing

There are ordinary anodized and hard anodized, can be clean and decontamination, beautify the surface, variety of colors

Power coating

Power coating

It can prevent corrosion, beautify appearance, improve wear resistance, color optional

Spray paint

It can prevent corrosion, beautify appearance,color optional. The wear resistance is not as good as powder coating.

casting polishing+chrome plate 1

Electroplate

It can prevent corrosion, increase aesthetics, improve wear resistance, optional color

Electrophoresis-re

Electrophoresis

It can prevent corrosion, increase aesthetics, improve wear resistance, optional color,more corrosion resistant than electroplate.

Why choose Mastersdex

Complex-Design

Diverse processing capabilities

We have the ability of multiple processing processes to meet the needs of customers for different parts and products, providing one-stop solutions

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Flexible customization services

Whether the customer needs are small batch production or large-scale production, we can flexibly adjust the production plan and provide personalized customized services to meet the specific needs of different customers

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Strict quality control

We implement a strict quality management system to ensure that every processing step is in line with standards, and regular quality checks are carried out to ensure the accuracy and consistency of the final product

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Worldwide Shipping Solution

Through international express DHL/ FEDEX, you will receive qualified parts within 3 to 7 days. For bulk orders, sea or rail transportation services are provided to reduce the shipping cost.

Other Machining Services

CNC machining

Casting and CNC machining are closely linked. Casting can efficiently form complex shapes of blank parts, but the accuracy is limited. CNC machining uses high precision to correct the size and finish the surface of the cast blank, and the two advantages complement each other.

Sheet Metal Fabrication Service

Get your sheet metal fabrication parts in 20+ metals. From one-off prototyping and on demand production, all your needs can be met here.

3D Printing Service

Get your parts 3D printed with SLA, SLS,MJF, SLM or FDM. Surface treatment like polishing, dyeing, and painting are all available.

Vacuum Casting Services

Vacuum casting is a custom manufacturing method used for the production of small series of functional plastic parts, materials including ABS-Like,PMMA-Like,PC-Like,PP-Like,Rubber-Like,Silicone.

Precision CNC Machining FAQs

The two primary CNC machining processes are CNC turning and CNC milling. Other machining processes include drilling, gear hobbing and electrical discharge machining,grinding among others.
Parts machined with metal will follow ISO 2768-m (medium) or ISO 2768-f (fine). Parts machined with plastics will follow 2768-m (medium). Geometric tolerances down to ± 0.001mm are possible but must be clearly indicated in technical drawings. We can achieve tighter tolerances on shafts with up to H7 fits with manual quoting and on occasion tighter.
We offer CNC milling (3-axis, 3+2-axis and 5-axis) and turning. Milled parts can be machined up to 2000 x 1500 x 300 mm for 3, 3+2 axis CNC milling. For 5-axis milling, the maximum part size is 650 x 650 x 300 mm. The maximum diameter for CNC turning is 431mm, length 990 mm. Minimum part dimensions recommended are around 2 x 2 x 2mm.The minimum for feature dimensions is 0.5 mm.
We offer CNC milling (3-axis, 3+2-axis and 5-axis) and turning. Milled parts can be machined up to 2000 x 1500 x 300 mm for 3, 3+2 axis CNC milling. For 5-axis milling, the maximum part size is 650 x 650 x 300 mm. The maximum diameter for CNC turning is 431mm, length 990 mm. Minimum part dimensions recommended are around 2 x 2 x 2mm.The minimum for feature dimensions is 0.5 mm.
Deburing and edge breaking are standard procedures for all CNC machined parts. lf there are any critical edges that should be left sharp, they must be clearly indicated in technical drawings. Surfaces will be free of defects such as scratches, dents, stains, blemishes, hanging marks, minor defects. Surfaces indicated ascritical (primary (a) side, as indicated on the technical drawing) will be free of mill steps and other marks. For the secondary (b) side, minor hanging marks and up to 2 minor defects are acceptable. A number of post-processing and finishing methods can be applied to improve the surface roug hness, visual properties andwear resistance of machined parts.
We offer UNF, UNC, and metric threads for machining along with coil and key inserts. These are available on both milled or turned CNC parts.

Mastersdex caters to both one-off prototype and large-scale production runs. Thus, there is typically no strict MOQ. Whether you need a single part or thousands, Mastersdex aims to provide a solution.

Lead times can vary based on the complexity of the design, the chosen material, and the current workload. However, one of the advantages of CNC machining is its speed, especially for simpler parts. Once the setup is complete, machining times can be relatively quick. Parts machined as fast as 1 day! But for an accurate estimate, it’s best to request for quotes directly.
Product designers and engineers choose CNC machining to rapidly produce prototypes and production parts. The manufacturing technology offers a high level of precision, engineering-grade materials, quick-turn lead times.
Industries that use CNC machining include aerospace, automotive parts manufacturing, medical machine manufacturing, transportation, defense, and marine industries, along with oil and gas industries and electronics. CNC machining has allowed these industries to become more efficient at mass-producing custom CNC parts.

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