Shenzhen Alu Rapid Prototype Precision Co., Ltd.

Metal casting is a manufacturing process where molten metal is poured or injected into a mold to form a solid part with a specific shape upon cooling. It’s a versatile and widely used method for producing metal components, from simple to complex geometries, and is employed in industries like aerospace, automotive, medical, and industrial manufacturing. While not a primary focus of Shenzhen Alu Rapid’s services (which emphasize CNC machining, 3D printing, and sheet metal fabrication), metal casting may be offered for specific prototyping or production needs.

Key Aspects of Metal Casting

Process:

Mold Creation: A mold (made of sand, metal, or ceramic) is designed to match the desired part’s shape, often with cavities for complex features.

Melting: Metal (e.g., aluminum, steel, or zinc) is melted in a furnace to a liquid state.

Pouring/Injection: Molten metal is poured or injected into the mold.

Cooling and Solidification: The metal cools and solidifies, taking the mold’s shape.

Mold Removal: The casting is removed, and excess material (e.g., sprues) is trimmed.

Post-Processing: Finishing processes like machining, polishing, or coating refine the part.

Types of Metal Casting:

Sand Casting: Uses sand molds for large, less precise parts (e.g., engine blocks). Cost-effective but lower precision.

Die Casting: Injects molten metal into steel molds under high pressure for high-volume, precise parts (e.g., automotive components).

Investment Casting (Lost-Wax Casting): Uses wax patterns and ceramic molds for intricate, high-precision parts (e.g., turbine blades).

Permanent Mold Casting: Uses reusable metal molds for medium-volume production (e.g., pistons).

Centrifugal Casting: Spins the mold to create hollow parts like pipes.

Materials: Aluminum, steel, stainless steel, zinc, magnesium, copper, bronze, and titanium.

Advantages:

Versatile for complex shapes and large parts.

Cost-effective for high-volume production (die casting) or large components (sand casting).

Wide material compatibility.

Limitations:

High initial tooling costs (e.g., die casting molds).

Lower precision than CNC machining for some methods.

Longer lead times for mold creation compared to 3D printing or CNC.

Applications:

Prototyping: Investment casting for precise prototypes (e.g., medical or aerospace parts).

Production: Die casting for automotive parts, sand casting for industrial components.

Engine blocks, pump housings, gears, and decorative hardware.