MetCast
MetCast — Casting Division
Division · 01

Casting — sand, shell, investment & pressure die casting.

From thin-section investment castings and high-volume green sand to heavy no-bake mouldings, resin-shell precision and high-pressure aluminium/zinc die casting — MetCast's casting division delivers complex, traceable and dispatch-ready metallurgy across grey iron, ductile iron, steel and non-ferrous alloys.

0.05 – 2,500 kg
Range
30+ Grades
Materials
5
Routes
9 Methods
Inspection
Foundry pouring molten metal
Process Portfolio

Five casting routes — selected
by geometry, volume and material.

Process is selected from a single engineering brief: section thickness, expected volume, surface finish, mechanical property targets and downstream machining envelope all drive the choice.

▸ ROUTE

Green Sand

High-pressure green-sand molding for serial-volume ferrous and non-ferrous components — automotive, agricultural, municipal, hydraulic.

▸ ROUTE

No Bake

Chemically-bonded sand for heavy, large-section parts — pump bodies, valve casings, mill stands, process equipment.

▸ ROUTE

Shell Mold

Resin-coated sand shells for dimensional precision in mid-volume automotive, hydraulic and gear-blank components.

▸ ROUTE

Investment

Lost-wax route for thin sections, complex geometry and superior finish — stainless, duplex and super-alloys.

▸ ROUTE

Pressure Die

Aluminium HPDC and zinc PDC — net-shape, repeatable, high-finish for automotive, electrical, lighting and hardware.

01 · Investment Casting

Lost-wax precision for complex geometry & superior finish.

Wax patterns are injected, assembled into clusters, repeatedly dipped in ceramic slurry to build a refractory shell, then dewaxed, preheated and poured with controlled chemistry. The result: near-net-shape parts with dimensional repeatability, fine surface finish and minimal machining stock.

STEP 01
Wax Pattern
→
STEP 02
Cluster Assembly
→
STEP 03
Shell Building
→
STEP 04
Dewaxing
→
STEP 05
Preheating
→
STEP 06
Pouring
→
STEP 07
Knockout
→
STEP 08
Finishing
→
STEP 09
Inspection

Typical Materials

  • Stainless 304 / 316 / 321
  • Duplex CD3MN
  • Super Duplex CE3MN
  • Inconel 625 / 718
  • LCB / LCC

Why Investment

  • Wall thickness from 2 mm
  • Ra 3.2 µm as-cast
  • Complex internal passages
  • Minimal machining stock

Quality Checkpoints

  • Wax pattern dimensional
  • Shell weight & cure
  • Pour temperature trace
  • Spectro per heat
  • Dimensional + NDT
02 · Green Sand Casting

High-pressure serial production for ferrous & non-ferrous components.

STEP 01
Pattern Setup
→
STEP 02
Sand Preparation
→
STEP 03
Molding & Coring
→
STEP 04
Mold Assembly
→
STEP 05
Melting
→
STEP 06
Pouring
→
STEP 07
Shakeout
→
STEP 08
Fettling
→
STEP 09
Inspection

Typical Materials

  • Grey Iron GG-20 / 25 / 30
  • Ductile Iron GGG-40 / 50 / 60 / 70
  • Carbon Steel WCB / WCC
  • Aluminium ADC-12

Why Green Sand

  • High-volume cost efficiency
  • Wide weight envelope
  • Re-circulated sand system
  • Repeatable mechanisation

Quality Checkpoints

  • Sand permeability / GFN
  • Mold hardness
  • Pour temperature
  • Spectro per heat
  • Dimensional gauging
03 · No Bake Casting

Chemically-bonded sand for heavy, large-section components.

STEP 01
Pattern Layout
→
STEP 02
Chemically-Bonded Sand
→
STEP 03
Mold & Core Cure
→
STEP 04
Mold Assembly
→
STEP 05
Melting
→
STEP 06
Controlled Pour
→
STEP 07
Knockout
→
STEP 08
Heat Treatment
→
STEP 09
Inspection

Typical Materials

  • Cast Steel GS-Cast / WCB / WCC
  • Ductile Iron EN-GJS-400/500
  • High Manganese Steel
  • High Chromium Iron

Why No Bake

  • Pieces up to 2,500 kg
  • Excellent surface integrity
  • Stable dimensional accuracy
  • Low gas-defect risk

Quality Checkpoints

  • Binder ratio control
  • Bench / strip-time
  • Mold hot-strength
  • 100% UT on critical sections
04 · Shell Molding

Resin-coated sand precision for mid-volume runs.

STEP 01
Heated Pattern Plate
→
STEP 02
Resin-Coated Sand Dump
→
STEP 03
Shell Cure
→
STEP 04
Strip & Stack
→
STEP 05
Pouring
→
STEP 06
Cooling
→
STEP 07
Knockout
→
STEP 08
Finishing
→
STEP 09
Inspection

Typical Materials

  • Grey & Ductile Iron
  • Carbon Steel
  • Low-Alloy Steel

Why Shell

  • Dimensional accuracy
  • Smooth surface finish
  • Thin-wall capability
  • Reduced fettling

Quality Checkpoints

  • Shell thickness
  • Cure cycle
  • Mold stack alignment
  • First-piece dimensional
05 · Pressure Die Casting

High-pressure aluminium & zinc die casting — engineered for automotive, electrical & hardware.

Aluminium HPDC delivers net-shape housings, brackets and enclosures with mechanical strength and dimensional stability. Zinc PDC complements with thin-wall capability, superior surface finish and tight precision — ideal for hardware, lock components and decorative parts.

Aluminium HPDC Alloys

  • ADC-12 / A380
  • ADC-10 / A360
  • AlSi10Mg
  • AlSi9Cu3 (EN AC-46000)
  • AlSi12 (EN AC-44100)
Aluminium HPDC cell
STEP 01
Tool Design
→
STEP 02
Mold-Flow Analysis
→
STEP 03
Die Manufacturing
→
STEP 04
Melting
→
STEP 05
HPDC Injection
→
STEP 06
Trimming
→
STEP 07
CNC Machining
→
STEP 08
Surface Finishing
→
STEP 09
Inspection

Zinc PDC Alloys

  • ZAMAK-2 / 3 / 5 / 7
  • ZA-8 / ZA-12 / ZA-27
  • Spectro-verified composition

Post-Processing

  • Trim & deflash
  • Shot blast / vibratory
  • CNC machining
  • Anodising / powder coat / chromate
  • Plating (Cu / Ni / Cr) for zinc

PDC Quality

  • X-ray internal porosity
  • Helium / pressure-decay leak
  • Density (Archimedes)
  • VDG P201 porosity rating
  • CMM dimensional
Engineering Support

Casting is engineered before it is poured.

Every casting project at MetCast begins in the engineering room — not at the furnace. Process selection, gating, risering, simulation and machining strategy are agreed before the first pattern is cut.

▸ ENG

DFM Review

Castability check on draft, ribs, hot spots and machining datum strategy.

▸ ENG

Casting Simulation

Mould-flow & solidification simulation (MAGMA / ProCAST) — predict shrinkage and porosity before tooling.

▸ ENG

Pattern Development

Wood, resin, aluminium or epoxy pattern construction with engineered shrinkage and machining allowances.

▸ ENG

Tooling Development

Core boxes, die-sets, HPDC tooling — designed, manufactured and validated in-house.

▸ ENG

Gating Design

Engineered ingate geometry for laminar fill, slag separation and yield optimisation.

▸ ENG

Riser Design

Feeder placement, sleeve selection and modulus calculation for sound mass-feeding.

▸ ENG

Metallurgical Validation

Heat chemistry, inoculation, nodularity & microstructure validated per heat.

▸ ENG

Machining Planning

Datum strategy, fixture concept and turn / mill route locked at quotation stage.

▸ ENG

Inspection Planning

ITP, CMM strategy, NDT method selection and PPAP-style documentation.

Process Gallery

From pattern shop to inspection bay.

Pouring & Moulding

Pouring & Moulding

Controlled-temperature pour into green-sand and no-bake moulds.

Investment Pattern

Investment Pattern

Wax cluster assembly prior to ceramic shell building.

Pressure Die Casting

Pressure Die Casting

Aluminium HPDC cell — net-shape automotive housings.

Inspection Bay

Inspection Bay

Dimensional, NDT and metallurgical inspection per lot.

Applications

Casting components across ten industrial sectors.

▸ Automotive Components
▸ Railway Components
▸ Pump Bodies
▸ Valve Bodies
▸ Gearbox Housings
▸ Hydraulic Components
▸ Compressor Components
▸ Energy Sector Components
▸ Construction Equipment Parts
▸ Municipal Infrastructure Components
Automotive cast components
Pump & valve cast bodies
Materials Library

Ferrous, stainless, duplex, nickel and non-ferrous alloys.

Ferrous

  • Grey Iron (GG-20/25/30)
  • Ductile Iron (GGG-40/50/60/70)
  • ADI — Austempered Ductile Iron
  • Carbon Steel WCB / WCC
  • High Chromium Iron
  • High Manganese Steel (Hadfield)

Stainless & Super Alloys

  • Stainless 304 / 316 / 321
  • Duplex Stainless (CD3MN)
  • Super Duplex (CE3MN)
  • Inconel 625 / 718
  • Monel M-35-1

Non-Ferrous

  • Aluminium ADC-12 / AlSi10Mg
  • Zinc ZAMAK 3 / 5
  • Brass (CuZn alloys)
  • Bronze (Sn / Al Bronze)
Validation Streams

Five validation streams. Documented per lot.

Metallurgical inspection lab
  • Chemical Testing — OES spectrometer per heat with element traceability
  • Mechanical Testing — Tensile, yield, elongation, hardness, Charpy impact
  • Metallography — graphite morphology, nodularity, phase analysis
  • Dimensional Inspection — CMM, gauges, height & bore measurement
  • Non-Destructive Testing — UT · RT · MPI · DPI per ASNT/EN ISO 9712

Send a casting drawing — receive route recommendation, DFM critique and indicative cost in 24 hours.

Casting Inquiry
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