Casting Services

Fractory’s metal casting services ensure your growing needs never outpace your production capabilities. Our capabilities include a broad set of casting processes, including specialist processes, and our Project Engineers are ready to assist in planning and execution, making certain your projects are completed cost-efficiently and to high-quality standards.

Casting Capabilities

Available processes
Available processes Die casting, sand casting, investment casting, centrifugal casting, etc.

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Manufacturing for 2500+ Businesses
  • Scale your production without switching suppliers, we can handle single orders upwards of 2 million pounds.
  • Discuss your metal casting project with Fractory’s engineers for cost-efficient solutions.
  • Fractory handles everything from quoting to delivery, including quality control.
  • A single point of contact simplifies project management, freeing up time for value-added activities.
  • Competitive quotes and lead times
  • UK-wide delivery to your selected address.

Die Casting

Die casting produces high-precision metal parts by injecting molten metal into steel molds under high pressure. It is widely used for creating complex components with excellent dimensional accuracy, smooth surface finishes, and minimal post-processing requirements.

Die casting provides considerable benefits, including fast production cycles, excellent material efficiency, and the capability to create complex geometries. Nonetheless, it demands a significant upfront investment and is best suited for medium to high-volume production runs.

Die casting is most suitable for producing small to medium-sized components as there are practical limitations on the weight of die-cast parts. As the size of the casting increases, the cost of the process also increases at a greater rate, rendering the process unfeasible beyond the inflection point. In such cases, alternative casting methods may be more cost-efficient.

There are two main types of die casting: hot chamber and cold chamber. Hot chamber die casting is faster and best suited for low-melting-point metals such as zinc and magnesium, while cold chamber die casting is used for higher-melting-point metals like aluminium and copper.

Sand Casting

Sand casting is the most widely used casting process in the world, accounting for over 60% of all cast metal products. Its popularity stems from its versatility with various metal types and product sizes, as well as its cost efficiency.

Although it is an ancient process, sand casting has undergone remarkable advancements, keeping it highly relevant in today’s manufacturing landscape. The method is compatible with diverse production setups, including single-piece, batch, and mass production. It is used to create a wide range of components, from small parts to large structures like engine blocks and locomotive parts.

The process begins with creating a mould by packing sand around a pattern that replicates the final product. The sand mould is then assembled, molten metal is poured into the cavity, and once the metal solidifies, the casting is removed and undergoes finishing.

Key properties of the sand—such as refractoriness, permeability, and thermal conductivity—play a crucial role in achieving surface quality and process efficiency. One limitation of sand casting is the variability of surface finish. For products requiring high-quality finishes without extensive post-processing, die casting and investment casting are often preferred. However, with the right sand and optimised processes, sand casting can also produce good results.

Investment Casting

Investment casting, also known as precision or lost-wax casting, is a highly accurate metal casting method used to create complex parts with excellent surface finishes. The process begins by creating a wax pattern, which is coated with multiple layers of ceramic slurry to form a durable shell mould. After the wax is removed, molten metal is poured into the ceramic mould, allowed to solidify, and then separated to reveal the final casting.

This method is renowned for its ability to produce intricate shapes and fine details with minimal post-processing. It works with a wide range of metals, including carbon and stainless steel, aluminium, and brass, and is commonly used for applications requiring high precision, such as turbine blades and automotive components.

While investment casting offers great accuracy and smooth finishes, it is more time-intensive and costly than, for example, sand casting, making it best suited for medium to high-volume production or parts with complex geometries.

Centrifugal Casting

Centrifugal casting uses high-speed rotation to produce cylindrical components like pipes, bearings, and gear blanks. In this process, molten metal is poured into a spinning die, where centrifugal force evenly distributes the metal along the die’s surface, ensuring uniform thickness and excellent mechanical properties.

The process begins with preparing the die and applying a ceramic lining to ensure smooth casting and easy removal. Molten metal is then poured into the spinning die, where impurities are forced inward while the denser material solidifies outward. This controlled solidification enhances the part’s strength and uniformity.

Centrifugal casting is especially effective for creating long, hollow parts with consistent grain structure, and it eliminates the need for cores. However, it is best suited for simple cylindrical shapes and similarly to die casting, requires significant upfront investment, making it ideal for high-volume production.

Before Submitting Your RFQ

We ask for as much detail as possible with your RFQ. The more information you provide, the more accurate our pricing and lead time estimates will be.

  • Drawings – Engineering drawings should include all the information for manufacturing a product or a part. Additionally, include stress/load requirements to ensure the castings meet your expectations.
  • Estimated weight – This helps us with calculating costs and sourcing the materials, leading to more accurate estimates.
  • Secondary processing requirements – Specify any machining requirements for whole parts or specific faces, and also if any specialised heat treatment processes or coatings are needed.
  • Quantities – Provide us with both the initial and long-term estimates as future volumes affect pattern development – some materials are more suitable for longer-term runs, etc.
  • Expected lead time – Depending on the quantity and complexity of the parts, completing production runs for new parts might take up to 6 months. When agreed, smaller shipments can be sent out before the completion of the whole run. Keep in mind that subsequent production runs will require significantly less time.

Metal Casting FAQ

What metals can you cast?

We work with a wide range of metals, including carbon steel, stainless steel, aluminum, zinc, brass, and more. The choice of metal and the part geometry will determine the most suitable casting process.

Do you do the work in-house?

Fractory has a network of partners whose processes and services have been audited by us. This includes workplace safety, equipment standards, etc.

What casting process would suit our needs?

The choice of casting process depends on various factors – choice of metal, quantity, visual requirements, etc. If not sure, consult our in-house engineers.

Let us ease your workload! Order metal fabrication from Fractory and experience the benefits yourself: 1-1 engineering support, payment terms for companies, a single point of contact, competitive pricing, on-time deliveries and quality control.
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