MetCast
Quality & Engineering Excellence - MetCast
MC-Quality & Engineering Excellence

Quality is not inspected into a product. It is engineered into every process.

MetCast operates an integrated quality framework — ISO 9001 documentation, IATF 16949-aligned process discipline, an in-house metallurgical and dimensional laboratory, and the full APQP / PPAP / FMEA / MSA / SPC / CAPA / 8D toolset.

ISO 9001
Quality System
IATF 16949
Framework
In-house
Lab
APQP · PPAP · 8D
Tools
MetCast quality and metrology laboratory
// 00 Quality Philosophy

Quality is engineered into every process — from inquiry to delivery.

At MetCast Technologies, quality is integrated throughout the manufacturing lifecycle — from engineering review and supplier qualification through production, inspection, documentation, dispatch and delivery.

Our quality systems combine process control, material verification, dimensional validation, mechanical testing, metallurgical analysis and supplier quality management to ensure that every component meets defined technical requirements.

The objective is not to detect defects after manufacture — but to engineer the process so that defects cannot occur in the first place.

Quality System
ISO 9001
Framework
IATF 16949
NDT Methods
MPI · DPI · UT · RT
Mechanical Lab
In-house
Material Cert.
EN 10204 3.1
Quality Toolset
APQP · PPAP · 8D
// 01 Quality Management Approach

A controlled, traceable workflow from customer requirement to delivered part.

Every project moves through ten defined stages. Each stage has a documented owner, a documented input and a documented output — making the entire chain auditable end-to-end.

  1. 01

    Customer Requirements

    Drawings, specifications, material grade, applicable standards (EN, DIN, ASTM, API), inspection regime and end-application captured at inquiry stage.

  2. 02

    Engineering Review

    DFM review, route selection, tolerance feasibility, material substitution analysis and process risk assessment by a qualified manufacturing engineer.

  3. 03

    Process Planning

    Routing sheet, work-instructions, fixture/tooling plan, gauging plan and control-plan drafted before production release.

  4. 04

    Supplier Qualification

    Audited foundry / forge / machining partner selected from the approved vendor list; capability and capacity reconfirmed for the job.

  5. 05

    Production Control

    In-process checks, machine parameter logs, charge mix validation, SPC monitoring on critical characteristics.

  6. 06

    Inspection

    Dimensional, visual and surface inspection per control plan with calibrated gauges and CMM verification.

  7. 07

    Testing

    Chemistry, mechanical, metallographic and NDT performed in-house and at NABL-accredited partner laboratories.

  8. 08

    Documentation

    MTC (EN 10204 3.1), ISIR / FAIR, PPAP packages, NDT reports, heat-traceability and dispatch dossier compiled.

  9. 09

    Dispatch Approval

    Final QA sign-off, packing inspection, marking & traceability verification, dispatch clearance only after document set is closed.

  10. 10

    Customer Delivery

    Coordinated logistics, port-of-loading inspection where required, post-delivery support and CAPA closure for any field feedback.

// 02 Chemical Analysis & Metallurgical Control

Material verification & metallurgical control.

Every heat is chemically verified before pouring and again on the finished casting. Spectrometer chemistry, combustion-based carbon & sulphur analysis and microstructure evaluation are recorded against batch identifiers and travel with the component.

▸ METALLURGY

Spectrometer Analysis

Multi-element OES chemistry per heat with calibration drift monitoring.

▸ METALLURGY

Carbon & Sulphur Analysis

Combustion-based C/S analyser for ferrous alloys.

▸ METALLURGY

Chemical Composition

Heat-by-heat verification against EN / ASTM grade limits.

▸ METALLURGY

Alloy Control

Charge-mix calculation, scrap segregation, ferro-alloy addition discipline.

▸ METALLURGY

Heat Verification

Unique heat code, tapping temperature log, pouring window control.

▸ METALLURGY

Charge Mix Validation

Documented charge sheet for every melt, cross-checked before tapping.

▸ METALLURGY

Nodularity Verification

Wedge sampling and microscopic nodularity count for SG iron.

▸ METALLURGY

Inoculation Validation

Late-stream inoculation control and fade-time monitoring.

▸ METALLURGY

Microstructure Analysis

Phase distribution, graphite morphology and matrix evaluation.

Applications · Grey Iron · Ductile Iron · Steel Castings · Forgings · Pressure Die Castings
Optical emission spectrometer
Metallurgical microscope and microstructure
// 03 Mechanical Testing Laboratory

Mechanical property validation.

Mechanical testing verifies material performance and compliance with customer specifications and international standards. Specimens are extracted, machined and tested per ASTM, ISO and EN procedures and recorded on traceable test reports.

Tensile testing machine
Hardness testing machine
▸ TEST

Tensile Testing

Universal testing machine for proof of mechanical strength.

  • · Yield Strength (Rp0.2)
  • · Ultimate Tensile Strength (Rm)
  • · Elongation at Fracture (A%)
  • · Reduction of Area (Z%)
▸ TEST

Impact Testing

Charpy V-notch with sub-zero conditioning chamber.

  • · Impact Energy (Joules)
  • · Low-temperature performance to −60 °C
  • · Material toughness validation
▸ TEST

Hardness Testing

Brinell, Rockwell and Vickers stations under calibration control.

  • · Surface Hardness
  • · Core Hardness
  • · Heat-treatment validation
▸ TEST

Compression Testing

Load-bearing validation for forged and cast structural components — confirms mechanical performance under service load.

Applications · Castings · Forgings · Machined Components · Pressure Die Cast Components
Metallography laboratory
// 04 Metallography Laboratory

Microstructure analysis & metallurgical evaluation.

Polished and etched specimens are evaluated under metallurgical microscopes to confirm phase distribution, graphite morphology, grain structure and absence of harmful constituents.

  • ✓ Graphite structure evaluation — flake / nodular morphology
  • ✓ Nodularity & nodule count per ISO 945
  • ✓ Matrix evaluation — ferrite, pearlite, bainite, martensite
  • ✓ Ferrite & pearlite percentage measurement
  • ✓ Carbide detection & decarburisation check
  • ✓ Grain structure analysis & ASTM grain size determination
  • ✓ Inclusion rating per ASTM E45 / DIN 50602
  • ✓ Defect investigation — micro-shrinkage, porosity, cracks
Applications · Grey Iron · Ductile Iron · Steel · Forgings · Pressure Die Castings
// 05 Dimensional Inspection

Dimensional validation & precision measurement.

All metrology equipment is under documented calibration control. Inspection is performed against the latest released drawing revision with full GD&T evaluation and capability indices for critical characteristics.

▸ METROLOGY

CMM

Touch-probe and scanning CMM with full GD&T evaluation against CAD.

▸ METROLOGY

Height Gauge

Digital height-gauge stations for repeatable verification.

▸ METROLOGY

Micrometers & Verniers

Calibrated digital and analogue precision instruments.

▸ METROLOGY

Bore Gauges

Two- and three-point bore gauging with master setting rings.

▸ METROLOGY

Thread Gauges

Plug, ring and pitch gauges under calibration control.

▸ METROLOGY

Profile Measurement

Optical profile projector and contour tracing systems.

▸ METROLOGY

Surface Roughness Tester

Skidless contact profilometry — Ra, Rz, Rmax.

▸ METROLOGY

Master & Snap Gauges

Job-specific gauges for high-volume serial inspection.

Coordinate measuring machine
▸ Parameters Verified
· Dimensional Accuracy
· Geometric Tolerances
· Surface Finish
· Concentricity
· Runout
· Flatness
· Parallelism
· Perpendicularity
Non-destructive testing on industrial component
// 06 Non-Destructive Testing

Non-destructive examination.

NDT is performed by ASNT / EN ISO 9712 qualified personnel and used wherever surface or internal integrity is critical to service performance.

▸ NDT

MPI

Magnetic Particle Inspection — surface and near-surface discontinuities on ferromagnetic parts.

▸ NDT

DPI

Dye Penetrant Inspection — surface-breaking defects on ferrous and non-ferrous materials.

▸ NDT

Ultrasonic Testing

UT for internal flaw detection and wall-thickness verification.

▸ NDT

Radiography Testing

Film and digital RT for porosity, shrinkage and inclusion characterisation.

Applications · Castings · Forgings · Pressure Die Cast Components · Critical Engineering Parts
Purpose · Surface defect detection · Internal defect detection · Crack detection · Integrity validation
// 07 Forging Quality Control

End-to-end forging quality assurance.

Forging integrity depends on disciplined control at every stage — from billet identity to final NDT. Each forging is tracked through a documented process card containing heat number, billet weight, heating temperature, press cycle, heat-treatment lot and final inspection results.

Incoming Material Verification

Spectro + MTC review against the raw-material specification.

Billet Identification

Hard stamp / paint marking with heat number and grade traceability.

Heating Temperature Control

Pyrometer-monitored furnace cycle within forging window.

Forging Process Monitoring

Press tonnage, blow count and die temperature recorded per cycle.

Heat Treatment Validation

Normalising, Q&T or annealing cycles validated by hardness and microstructure.

Hardness Verification

Surface and core hardness mapping after heat-treat.

Mechanical Testing

Tensile, impact and where applicable, through-thickness testing per lot.

Dimensional Inspection

First-piece + sampling plan as per AQL / customer requirement.

NDT Testing

MPI / UT for sub-surface and internal defect detection.

Final Inspection

QA sign-off, marking, preservation and dispatch authorisation.

Forging press production
Pressure die casting cell
// 08 Pressure Die Casting Quality

Specialised QA controls for HPDC components.

HPDC quality is governed by tool condition, shot parameters and porosity behaviour. Tools are qualified through T0 / T1 / T2 sampling and released only after dimensional capability and pressure-tightness are demonstrated.

Mold Qualification

T0/T1/T2 sampling, MSA on critical dimensions, mold release approval.

Tool Validation

Shot-curve, intensification and die-temperature validation per cavity.

Porosity Evaluation

Metallographic porosity rating per VDG P201.

X-Ray Inspection

Internal porosity, shrinkage and inclusion mapping.

Leak Testing

Pressure-decay and helium-trace for fluid-tight housings.

Pressure Testing

Hydrostatic verification on pressure-bearing housings.

Dimensional Validation

ISIR with Cp/Cpk on critical characteristics.

Surface Finish Evaluation

Cosmetic and functional surface acceptance per defect catalogue.

Production Approval

PPAP-style release with control plan, FMEA and capability data.

Applications · Aluminium HPDC · Zinc HPDC
// 09 Plastic Component Quality Control

Polymer & hybrid quality systems.

Plastic quality starts at the resin batch and ends with packaged finished goods. MetCast applies a disciplined inspection regime across raw material, tool, first-article, in-process and dispatch stages — including metal-plastic hybrid assemblies and our own PU tactile and elevator-bucket product lines.

Injection moulding production

Raw Material Verification

Resin batch identification, MFI / moisture validation before drying.

Mold Qualification

T0/T1/T2 sampling with MSA, mold release sign-off.

First Article Inspection

AS9102-style FAIR with ballooned drawing review.

Dimensional Validation

Capability indices (Cp/Cpk) on critical characteristics.

Visual Inspection

Cosmetic acceptance per defect catalogue; lighting standards defined.

Functional Testing

Fit, snap-force, latch retention, leak and assembly fit checks.

Assembly Validation

Hybrid metal-plastic assemblies validated for retention and concentricity.

Production Monitoring

Process parameter logs — barrel temp, injection pressure, cycle time.

Packaging Inspection

Pack format, labeling, lot traceability and dispatch readiness.

▸ Materials
PP · ABS · Nylon (PA6 / PA66 GF) · POM · PC · PBT · Engineering Plastics · Hybrid Metal-Plastic
▸ Applications
Custom Plastic Parts · Metal-Plastic Assemblies · PU Tactile Products · Elevator Buckets
// 10 Advanced Quality Systems

The complete AIAG / IATF toolset.

MetCast deploys the full advanced quality planning toolset across new-product introduction, serial production and supplier development.

APQP

Advanced Product Quality Planning — structured NPI from concept to PPAP submission.

PPAP

Production Part Approval Process — full Level 3 documentation package on request.

FMEA

Design and Process FMEA — failure modes ranked by severity, occurrence, and detection ratings.

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