Manufacturing Processes

One-stop solution for a wide range of casting processes

One-stop solution for a wide range of casting processes, including No Bake Molding, Investment Casting, Vacuum Process, VLICSS, and Profile Core and Flaskless Molding. Good Casting Capacity: 1,000 MT/Month.

Alphaset No Bake System Casting

Alphaset No Bake System Casting uses chemically bonded sand molds that cure at room temperature. This process offers excellent dimensional accuracy and surface finish for complex castings.

Applications

  • Large and medium-sized castings
  • Complex geometries
  • Ground engaging tools

Key Advantages

  • Fast production cycles
  • Superior dimensional accuracy
  • Excellent surface finish
  • Cost-effective production

Investment Casting

Investment casting using wax-based processes. Creates precise castings with excellent surface finish and tight tolerances, ideal for intricate designs.

Applications

  • Precision components
  • High-value items
  • Complex internal features

Key Advantages

  • Exceptional surface finish
  • Tight tolerances
  • Complex details possible
  • Minimal post-processing

VLICSS

VLICSS (Vacuum Lost Investment Casting with Sintered Shell) combines the Fast Cast Process with vacuum lost foam casting technology. Foam patterns vaporise during metal pouring under vacuum conditions, while the sintered shell ensures exceptional dimensional accuracy and surface finish for near-net-shape components.

Applications

  • Precision components
  • Complex geometries
  • High-detail parts
  • Near-net-shape castings

Key Advantages

  • Near-net-shape accuracy
  • Excellent surface finish
  • Complex shapes possible
  • Minimal material waste
  • Reduced machining
  • Minimal draft requirements

Vacuum Moulding Process

Vacuum moulding process utilizes vacuum assistance during the moulding phase to ensure consistent quality and eliminate defects.

Applications

  • High-integrity components
  • Critical applications
  • Quality castings

Key Advantages

  • Eliminates porosity
  • Superior mechanical properties
  • Enhanced structural integrity
  • Consistent quality

Vertical Pouring Process

Vertical pouring process ensures optimal metal flow and filling characteristics for specific casting geometries.

Applications

  • Specialized casting geometries
  • Controlled metal flow applications

Key Advantages

  • Optimal metal flow
  • Improved filling characteristics
  • Reduced turbulence

Vertical Moulding Process

Vertical moulding process provides efficient production for specific casting requirements with vertical orientation.

Applications

  • Specific casting orientations
  • Production efficiency applications

Key Advantages

  • Efficient production
  • Optimized for specific geometries
  • Consistent results

V-Process

V-Process (Vacuum Molding Process) uses vacuum to hold unbonded sand in place during casting, producing high-quality surface finish.

Applications

  • No Bake applications
  • High surface finish requirements

Key Advantages

  • Excellent surface finish
  • No binders required
  • Environmentally friendly

Vacuum Counter Gravity (VCG)

VCG (Vacuum Counter Gravity) places the shell inside a vacuum chamber with its fill pipe facing downward. The chamber is sealed and lowered into the molten metal. A vacuum pulls the metal into the mould, ensuring complete filling. As the metal begins to solidify, the vacuum is released and the remaining metal in the sprue flows back into the melt. Only a small remaining piece is subsequently removed.

Applications

  • High-integrity components
  • Complete mould filling requirements
  • Critical applications

Key Advantages

  • Complete mould filling
  • Minimal waste
  • Superior metal flow control
  • Clean process

Profile Core and Flaskless Molding

Profile Core and Flaskless Molding combines profile-core sand casting with flaskless cake-mold techniques for efficient, flexible production. The process eliminates the need for traditional flask assemblies, enabling faster cycle times and optimised sand usage for a wide range of casting geometries.

Applications

  • Flaskless casting production
  • Profile core applications
  • Specialised casting requirements
  • Optimized sand usage

Key Advantages

  • Faster cycle times
  • Cost-effective production
  • Flexible for varied geometries
  • Similar benefits to No Bake

Process Capabilities & Differentiators

Castco offers various casting processes, rapid prototyping machines, in-house made SPMs, in-house gauge manufacturing, patented heat resistance trays, export-worthy packaging, and high-value items through investment process. Our comprehensive capabilities ensure we can meet diverse manufacturing requirements under one roof.