Metal Part Processes

Insty-Metal Parts: This is our fastest way to prototype metal cast parts. This is a perfect method for low-volume design verification. We can cast aluminum, iron, steel and zinc parts. Part size can be up to 13” X 15” X 18” and normal lead time is five days.

CNC High Speed Machining/Wire EDM: The CNC process is great for tight tolerance prototype, or projects in any volume for that matter, and in just about any material including: aluminum, zinc, magnesium, titanium, steel and most plastics. Additionally, our wire EDM service is designed for those very small, tight tolerance metal parts.

Spin Casting: Starts with a small pattern, which is carved into a rubber-like material. Heat and centrifugal force are applied so that the material retains the memory of the pattern. Then the zinc/aluminum material is poured and multiple parts are produced.

True - Cast: Great for prototyping precision castings with weight and thin-wall (.040) constraints. Plaster casting gives parts a surface finish similar to die casting. Ideal for low- to mid-volume cast aluminum 356-T6 and zinc parts. The parts can be as large as 36” X 36” X 36”.

Vacuum Casting: Starts with a pattern and then a layer of plastic. This is backed with sand and an additional layer of plastic. This sandwich of sorts is pulled under a vacuum to produce the tool. Then the metal is introduced and after it cools, the vacuum is released - giving us aluminum cast parts. The parts can be as large as 36” X 44” X 15”.

Sand Casting: A match-plate or parting-board is used as the pattern. A flask covers the pattern and holds the packed sand, which serves as the tool for the metal castings. After the metal cools, the sand is removed and the part is cleaned up. The part can be as large as 18” X 18” X 9”.

Permanent Mold: Here we cut a tool from steel or cast iron and it is put between a small clamp press. The metal is poured into the permanent mold and allowed to cool. Then the mold is opened, the part is released and the tool is re-used. The parts can be as large as 18” X 18” X 9”.

Investment Casting: We cut a tool and shoot wax into the mold. Then these patterns are added to a tree that is dunked multiple times into a slurry/sand, creating a shell-tool. The wax is melted away and metal is cast into the shell-tool. The tool is broken and the parts cleaned up.

Die Casting: For high volumes, this method gives you the most low-cost part available. Die cast tools are cut from a hardened material, into which molten metal is shot. It is allowed to cool, the part is removed and the tool is reused. The surface finish is the smoothest and porosity is the least of all the methods.