We produce high-precision, net-shape castings utilizing advanced automated shell moulding (shell-mold casting) technology. This process bridges the gap between traditional sand casting and high-end investment casting, offering our clients an exceptional combination of tight dimensional tolerances, rapid production speeds, and superior surface finishes. Our foundry is equipped to process a wide range of ferrous and non-ferrous metals, delivering components ranging from lightweight 50-gram parts up to high-density components weighing 35 kg.

Intricate Geometries & Near-Net Shapes

Thanks to the fine grain structure of our resin-bonded sand, we specialize in capturing intricate surface details, thin cross-sections (down to 1.5 mm), and complex internal configurations. This highly precise "near-net shape" capability allows our clients to minimize or entirely skip secondary grinding and machining operations. Common shell-moulded components we manufacture include:

1. Automobile & Diesel Engine Industries

• Engine Components: Crankshafts, Camshafts, Connecting rods, Cylinder heads, Rocker arms
• Power Transmission: Gear housings, Transmission cases, Lever arms, Bushings

2. General Engineering & Machine Tools

• Fluid Control & Hydraulics: High-pressure valve bodies, Hydraulic blocks, Pump impellers, Manifolds
• Structural & Support Components: Bearing shells, Brackets, Flanges, Bushings, Lever arms

3. Refrigeration & Air Conditioning

• Fluid & Thermal Control: High-pressure valve bodies, Pump impellers, Manifolds, specialized compressor brackets, and housings

4. Earth Moving Equipment’s & Heavy Industrial Machinery

• Heavy Duty Components: Bearing shells, Brackets, Flanges, Small-diameter pipe fixtures
• High-Stress Parts: High-pressure hydraulic blocks, Gear housings, Connecting rods

5. Textile Machinery

• Precision Mechanical Parts: Lever arms, Bushings, small Brackets, Flanges, and specialized gear housings tailored for high-speed loom and spinning mechanisms

Contact our engineering team today for design-for-manufacturing (DFM) solutions to optimize your draft angles and casting geometries for maximum efficiency.

Material Versatility (Ferrous & Non-Ferrous)

Our induction melting furnaces allow us to cast an extensive array of metallurgical compositions under strict temperature and atmospheric controls. Our material capabilities include:

• Cast Irons: Grey Iron (CI), Ductile / Spheroidal Graphite (SG) Iron, and Austempered Ductile Iron (ADI) for excellent wear resistance and vibration damping.

Inspection, Testing & Quality Assurance

To guarantee that every shell-moulded casting conforms to rigorous international standards and client blueprint specifications, we execute a multi-tier quality control regimen:

• Spectrochemical Melt Analysis: We utilize in-house ARL MAKE Optical Emission Spectrometers (OES) to analyze and certify the chemical composition of the liquid metal before every single pour.
• Microstructure Inspection. We have inhouse Olympus make Microscopy with Image analyse. So we can test microstructure with Nodularity, Grain Size, Inclusion test etc.
• Subsurface Integrity Testing: Internal soundness is monitored via Non-Destructive Evaluation (NDE) methods, including Ultrasonic Testing (UT), Radiographic/X-ray analysis, and Magnetic Particle Inspection (MPI) for ferrous parts.
• Mechanical Property Validation: Destructive testing, including Brinell/Rockwell hardness testing, tensile testing, and Charpy impact validation, is conducted per furnace heat lot to verify mechanical strength.

Finishing & Value-Added Machining Services

Following the shake-out process, castings are transferred to our automated finishing line where we provide full, turn-key, ready-for-assembly solutions:

• Shot Blasting & Surface Cleaning: Utilizing automated steel or aluminum shot blast chambers to remove residual sand-resin fragments and deliver a uniform, clean, matte finish.
• Fettling & Grinding: High-precision grinding to cleanly remove parting line flashes, gates, and risers.
• CNC Machining Department: For tolerances tighter than as-cast standards, our CNC machining division offers precise vertical and horizontal milling, high-speed turning, boring, tapping, and surface grinding.