Precision Casting

Hansheng Automation (Dongguan) Co., Ltd. is one of the most experienced manufacturers and suppliers of precision casting in China. If you're going to wholesale bulk cost-effective precision casting made in China, welcome to get pricelist and quotation from our factory. Also, customized service and OEM&ODM service are available.

Hansheng Automation is able to offer a wide range of metal casting services and can tailor the casting machining process to your specific project requirements, ensuring that your parts are suitable for their operating environment. Our custom casting capabilities meet the needs of manufacturers looking for unique and functional designs.In addition, as a professional supplier of tobacco packaging equipment parts, our gear factory provides standard and custom production (module 0.1-5.0), and our CNC machining center also provides customized parts processing services (super mirror ± 0.002mm).

Castings are metal products formed by injecting molten metals (such as iron, aluminum, copper, stainless steel, etc.) into prefabricated molds through the casting process, cooling and solidifying. Its core process advantage is that it can form complex geometric structures at one time, which is widely used in machinery manufacturing, auto parts, tobacco machine parts, lathe parts, aerospace and other fields.

1. Material diversity

There are many kinds of material options for castings, the common ones are iron castings, aluminum castings, copper castings, steel castings, etc. For different casting materials, the characteristics and application scenarios are also very different. Like what:

2. Design flexibility

The casting service can produce complex structures with internal cavities, special-shaped surfaces and other complex structures (such as the inner flow channel of hydraulic valve blocks), and support a variety of processes such as sand casting and investment casting. There are also differences in the accuracy level and characteristics of different processes, and I will use a table below to clearly analyze them.

Casting service requires a complex process step. From the design of the drawings before the casting to the quality inspection of the finished casting, the conventional process requires 16 steps, which are: Computer-Aided Design (CAD) Modeling, Mold/Master Model Fabrication, Wax Injection, Wax Pattern Assembly/Cluster Mounting, Shell Building, Shell Vibration/Devesting, Dewaxing, Shell Firing/Calcination, Molten Metal Pouring/Casting, Spectrochemical Analysis, Shell Removal & Casting Separation, Gating System Grinding/Hanging Tumbling/Barrel Finishing, Precision CNC Machining, Welding & Sub-Assembly Integration, and Quality Inspection Protocol. But depending on the choice of material and the choice between different casting processes, there will be subtle differences in these steps. I'll walk you through these steps to help you understand the process of casting service.

1. Computer-Aided Design (CAD) Modeling

This step uses software for 3D modeling, simulating metal flow, solidification shrinkage, etc. during the casting process to optimize the structural design to reduce defects.

2. Mold/Master Model Fabrication

After having the drawings, you can make the corresponding molds according to the drawings, and according to the customer's order size, you can choose different materials to make the molds. Choose wood molds or foam molds for small batch production, metal molds for mass production, and 3D printing sand molds for rapid prototyping.

3. Wax Injection

The materials commonly used in the wax injection process are low-temperature wax or resin, which are injected into the mold through a high-pressure wax injection machine to form a wax model consistent with the casting.

4. Wax Pattern Assembly/Cluster Mounting

The purpose of this step is to weld multiple wax patterns to the wax gating system (gates, risers) and improve the efficiency of batch casting.

5. Shell Building

Silica sol or water glass binder is used to alternately coat refractory materials (such as zircon sand, corundum sand) in multiple layers to form a high-temperature resistant ceramic shell.

6. Shell Vibration/Devesting

The unbonded loose sand layer is removed by vibrating equipment to ensure the finish of the inner wall of the shell.

7. Dewaxing

The wax mold is dissolved with high-temperature steam or hot water to form a hollow cavity, and the residual wax material needs to be completely removed.

8. Shell Firing/Calcination

Sintering at high temperatures of 900-1100°C enhances the strength of the shell and removes residual moisture and wax.

9. Molten Metal Pouring/Casting

Metal is melted in an electric/intermediate frequency furnace with vacuum casting (high-precision castings) or gravity casting (conventional parts).

10. Spectrochemical Analysis

Rapid determination of molten metal composition (e.g., C, Si, Mn) content using a direct emission spectrometer ensures that the material meets the standard.

11. Shell Removal & Casting Separation

Using a grinding wheel cutter or laser cutting, the casting is separated from the gating system.

12. Gating System Grinding/Hanging Tumbling/Barrel Finishing

This step is to carry out the surface treatment of the semi-finished product, remove burrs, flash, and improve the surface roughness (Ra≤3.2μm).

13. Ultrasonic Cleaning

High-frequency ultrasonic oscillation is used to remove residual sand and oxide scale inside the casting.

14. CNC Precision Machining

In order to improve the accuracy of casting products, it is necessary to use CNC machine tools to perform micron-level machining of key parts such as sealing surfaces and threaded holes.

15. Welding & Sub-Assembly Integration

For special-shaped castings, they are welded and spliced by TIG/MIG, or assembled with other components.

16. Quality Inspection Protocol

Inspect the surface defects of castings (porosity, shrinkage). And use 3-coordinate measurement to measure dimensional tolerances, X-ray flaw detection for internal cracks, pressure test tightness.

Next, a table is used to analyze in detail what are the differences and characteristics of different casting materials for casting services.

Hansheng Automation has been deeply involved in the foundry industry for many years and has rich experience in custom casting. The company has more than 10 professional and technical personnel and more than 50 sets of advanced equipment (such as high-precision three coordinates, altimeter, five-axis CNC machine tools, three-dimensional measuring instrument, spectrometer, finish meter, hardness tester, etc.), with the support of advanced mold manufacturing technology, it can achieve a casting tolerance accuracy of ±0.02mm. Through the triple quality control system (spectral analysis, X-ray flaw detection, three-coordinate inspection) to ensure that the products meet international standards, to provide customers in more than 60 countries around the world with zero defect services from design to delivery.

With the tenet of "customer first", we provide rapid prototype development, customized machining (CNC accuracy ± 0.02μm) and urgent order channels to help customers shorten the R&D cycle and reduce production costs. Whether it's aerospace precision gear parts or heavy machinery or machine tool structural parts, Hansheng Automation is able to meet all aspects of our customers' needs.

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