Casting and Moulding

Investment Casting

Wax Injection

Accurate and repeatable wax injection is a pre requisite for successful investment casting. The higher the dimension requirement the more critical is the method of wax pattern manufacture.

The facility is equipped with a Schott 25 ton side injection press with accurate control of the wax injection cycle that is essential for components with thin complex cores.

Die capacity 400mm L X 300mm W X 300 H wax injection capacity 1liter.

Wax Tree Injection

Wax tree assembly is done with hand tools as is done in industry. This process requires very good hand skills.

Jigging and fixtures are used for consistency in assembly.

MOULD MAKING

The facility is equipped with two dipping facilities.

Face coat facility
Back-up coat facility

Casting Technologies

Design for Casting

Castings Technology provides expertise in the processing and properties of cast metals together with casting design and manufacturing techniques.

Our team can help you to minimise the cost, time and risk involved in progressing a concept through to full scale production. The cost of dedicated pattern equipment necessitates a design to be ‘frozen’ prior to full production and our technology allows fluidity in the design process at the prototype phase and, even during full production, we are able to instantly modify patterns to meet design changes.

Using advanced software to simulate casting manufacture, our specialist engineers can optimise designs to facilitate the production of components to exacting specifications whilst considering cost and technical constraints. We have considerable experience in simultaneous engineering and can operate on a remote basis throughout the world.

We have the range of skills to support total project management of castings procurement, assisting you with:

Configuration optimisation
Material selection
Process selection
Procurement specifications
Third party surveillance and manufacture
Quality systems and assurance

Improving lead times

New Product Introduction

Our expertise and wide range of internal capabilities lend themselves to our unique NPI process which is supported by almost a century of experience and ranges from one off prototypes to multiple production batches.

The ability to rapidly design, mould and cast gives our clients the utmost flexibility in terms of component configuration.New Product Introduction (NPI)

Reverse Engineering

Even if engineering data and manufacturing drawings do not exist, by using the latest laser scanning techniques Castings Technology can produce manufacturing-ready 3D CAD geometries within hours.

This capability provides an ideal solution for breakdown scenarios together with casting legacy type components. We are able to create a detailed engineering drawing and can also provide any additional manufacturing services including metrology and finish machining.

Metrology

With extensive experience in 3D scanning and co-ordinate measurement using both contact and non-contact measurement technology, Castings Technology is uniquely positioned to inspect and accurately measure metal components at all stage of manufacture.

Casting Processes

Castings Technology is one of the world’s largest manufacturers of SLA patterns used to produce ceramic moulds for precision casting. This in-house process has enabled the development of a unique capability to rapidly manufacture patterns with extremely high dimensional compliance.

We are able to produce castings for international clients using the following moulding processes:

Ceramic Moulds

Castings Technology invented the Replicast® process which is combined with an in-house lost wax facility. We have also developed a customised shell system for titanium and other highly reactive alloys.

The company is uniquely positioned to offer technical assistance to investment casting producers in a wide range of processes, alloys and applications.

MEGAshell™ enables the production of large ceramic shell moulds to deliver the benefits of Replicast® for one-off and low volume castings. One piece ceramic moulds up to 2m³ can reduce net casting weight by up to 30% when compared with a sand cast equivalent when used in heavy section valves.

This process can result in savings in excess of 50% of machining costs when combined with all the other benefits of the Replicast® process. In addition, large near net shape castings particularly in challenging alloys can benefit from this process. Castings Technology has refined the MEGAshell™ technology for use with reactive alloys of titanium and zirconium.

3D sand printed moulds

3D sand printed moulds and cores can be extremely cost effective solutions as they offer high dimensional accuracy and close tolerances DCTG7 (casting dimensional tolerance) when compared with traditional sand moulds. Core production is available to support hybrid moulding requirements or flexible design modifications. Castings Technology can produce complex moulds and cores for oil, gas, aerospace, defence and automotive sectors without the need for dedicated tooling.

Counter gravity casting

This process is used to produce high integrity aluminium castings as it minimises turbulence, enhances mould filling efficiency whilst reducing the formation of oxides during the casting process. The technology is ideal for complex or thin walled complex castings.

Non-destructive Testing

Castings Technology employs highly qualified Non-Destructive Testing (NDT) specialists who have qualifications covering NDT disciplines for both castings and welding.

Our NDT department undertakes X-Ray examinations, ultrasonic testing, magnetic particle reviewing, and dye-penetrant inspection using equipment qualified to Aerospace standards.

Accreditations include:

X-Ray
Ultrasonic Testing
Magnetic Particle Inspection
Dye-Penetrant Inspection
Microscopic Examination
Chemical Analysis