Our Products
WE PRODUCE SHELLMOLDED GRADED ci AND sg iRON cASTINGS AND
PROTOTYPE CASTINGS WITH STATE OF THE ART 3D PRINTING TECHNOLOGIES
Foundry Products & Solutions
- Foundry products are defined as products that are derived from foundries. Foundries refer to workshops where metal castings are produced. Metal casting is a manufacturing process, where molten or liquid metal is poured into a mold which is made up of sand, metal, or ceramic. The mold contains a hollow cavity of the desired shape, to form geometrically complex parts. The metal casting process is applicable to all major metals that can be made into castings.
- common ones are iron, aluminum, magnesium, zinc, steel, and copper-based alloys. Metal castings are used in a wide range of applications such as in cars, trucks, planes, trains, mining and construction equipment, oil wells, pipes, toys, space shuttles, wind turbines, and nuclear plants. Manufacture of foundry products through the metal casting process is advantageous compared to other processes owing to its design flexibility, high production rate, and molding of large and complex parts.
- Additionally, easy way of fabricating wrought or cast products into complex structures while producing lightweight sheet metal parts is another advantage of foundry products.
- Increase in need for infrastructure and power generation facilities is fuelling the foundry products market. Growth in the automotive industry in emerging economies such as Japan, China, and India is also driving the foundry products market. Expansion in the MSME (micro, small, and medium enterprises) industry is also one of the factors propelling the foundry products market. Furthermore, rise in technological innovations and rapid industrialization and urbanization are augmenting the foundry products market.
- Based on product mix, the foundry products market can be segmented into grey iron, SG iron, non-ferrous, steel, and malleable, and others. The grey iron segment accounts for large share of the foundry products market owing to the wide use of grey iron in the automotive industry.
Graded Ductile Iron
SGI castings are our key production Items. We produce a wide range of Ductile Iron parts for a variety of applications.
Graded CI Castings
We Produce Graded CI Castings for General Purpose applications and special CI grades for special Applications.
Core Sand Additive
We manufacture foundry consummables and Premium Core Sand Additive is our revolutionary Product for Foundries to enhance Casting Quality and reduce rejections.
3D Printed Sand Molds
We have a range of 3D Printing and Prototyping services for materials like Plastic, Sand, Resins and Metals.
Prototype Castings
cater to a segment right in between 3D Printed Metal parts and Traditionally developed components.
3D Printed FDM Parts
We produce a variety of polymer parts with FDM 3D Printing. FDM is one of the earliest and most widely technologies to produce prototypes of Polymers.
Graded Ductile Iron
As with most grades of cast iron, ductile irons display:
- Good hardness and good wear resistance
- Good corrosion resistance
- Have tensile and yields strengths that vary widely across the various grades.
- Have compressive strengths that can be utilised more widely (than tensile strengths), with values tending to be about twice the tensile strength.
- Impact strengths are better than grey irons, with lower grades approaching values common for mild steel.
- Fatigue strengths are approximately 40 to 50% of tensile strengths.
- Electrical resistivities are significantly lower compared to grey irons
- Corrosion resistance is similar to grey iron
Graded CI Castings
A few common mechanical properties for cast iron include:
- Hardness – material’s resistance to abrasion and indentation
- Toughness – material’s ability to absorb energy
- Ductility – material’s ability to deform without fracture
- Elasticity – material’s ability to return to its original dimensions after it has been deformed
- Malleability – material’s ability to deform under compression without rupturing
- Tensile strength – the greatest longitudinal stress a material can bear without tearing apart
- Fatigue strength – the highest stress that a material can withstand for a given number of cycles without breaking
Core Sand Additive
- Sand additives are commonly used in molds and cores to reduce defects like veining, metal penetration and unacceptable surface finish. Historically, iron oxides have been the additives of choice, primarily red iron oxide (hematite, Fe2O3) and black iron oxide (magnetite, Fe3O4).
- However, these options can negatively impact the casting in terms of cost and quality. Engineered sand additives (ESAs) have been developed that are promoted to lower costs, improve veining resistance and/or reduce gas defects, but little comparative data is currently available to the steel casting industry.
- However, these options can negatively impact the casting in terms of cost and quality. Engineered sand additives (ESAs) have been developed that are promoted to lower costs, improve veining resistance and/or reduce gas defects, but little comparative data is currently available to the steel casting industry.
3D Printed Sand Molds
- Pattern creation – A two-piece metal pattern is created in the shape of the desired part, typically from iron or steel. Other materials are sometimes used, such as aluminium for low volume production or graphite for casting reactive materials.
- Mold creation – First, each pattern half is heated to 175-370 °C (350-700 °F) and coated with a lubricant to facilitate removal. Next, the heated pattern is clamped to a dump box, which contains a mixture of sand and a resin binder.
- Mould assembly – The two shell halves are joined together and securely clamped to form the complete shell mould. If any cores are required, they are inserted prior to closing the mould.
- Pouring – The mould is securely clamped together while the molten metal is poured from a ladle into the gating system and fills the mould cavity.
- Cooling – After the mould has been filled, the molten metal is allowed to cool and solidify into the shape of the final casting.
- Casting removal – After the molten metal has cooled, the mould can be broken and the casting removed. Trimming and cleaning processes are required to remove any excess metal from the feed system and any sand from the mould
Prototype Castings
Our prototyping capabilities include:
- 3D printed wax patterns created in-house within hours and immediately processed into fully functioning metal components.
- Rapid in-house tooling using your part geometry, produced manually to reduce lead time and cost.
- Specially formulated proprietary wax that is run through our highly automated investment casting process to ensure dimensional accuracy.
- The ability to prototype utilizing any of our metals—you are not limited by material offering.
- Capable of any secondary operation that the customer requires including: assembly, heat treating, welding, plating, painting, and more!
3D Printed FDM Parts
- Filament extruders, the most common and versatile variation which utilizes reels of thermoplastic filament.
- Pellet extruders, exchanging the filament for granules of plastic
- Chocolate extruders .
- Paste extruders, where any paste can be extruded. Common uses are with ceramics and food. Paste extrusion is sometimes left in its own category, as the paste is not necessarily a thermoplastic material