CASTING
Since 2003, X-PRO LLC has supplied global OEMs and industrial firms with an extensive range of precision-engineered casting products utilizing high-performance alloys.
Casting Methods & Capabilities
- Sand casting
- Rapid prototype casting
- Permanent mold casting
- Investment lost-wax casting
- Lost-foam fabrication casting
Advanced Casting Solutions
- Premium investment casting
- High-pressure die casting
- Centrifugal industrial casting
- Shell mold casting processes
- High-vacuum metal casting
Supported Metallurgical Materials
- Industrial aluminum alloys
- Austenitic & structural stainless steel
- Carbon and tool steel configurations
- Brass, copper, and bronze zinc alloys
- Pure zinc and zinc-aluminum alloys
Strategic Manufacturing Consultation: Engineering the Optimal Casting Process
- Target Surface Integrity: We evaluate the required surface finish parameters to eliminate unnecessary secondary abrasive blasting or polishing workflows.
- Extreme Dimensional Tolerances: Our team analyzes the geometric limits of your design to ensure strict net-shape casting accuracy.
- Production Volume Scaling: We match your projected quantities with the optimal mold type, balancing upfront hard tooling costs against component piece discounts.
- Metallurgical Compatibility: We consult on chemical compositions and liquid-flow dynamics to choose the ideal raw material configuration for your mechanical stress environment.
- Tooling & Pattern Optimization: We design custom pattern plates and core box equipment built for rapid cycle frequencies and long production lifespans.
- Total Manufacturing Cost Control: We analyze every production step to minimize material waste and deliver lower per-unit fabrication costs.
- Design for Manufacturing (DFM) Feedback: We proactively identify how a component’s geometric features interact with a selected casting method to prevent internal porosity or structural defects.
Each casting process has its advantages and disadvantages depended on the products needs
Sand Casting
Sand casting is one of the most popular and simplest types of casting, and has been used for centuries. Sand casting allows for smaller batches than permanent mold casting and at a very reasonable cost.
Shell Mold Casting
Our foundry in Zhejiang does shell mold casting for steel and aluminum. The resin sand mold enables complex geometries to be cast. We typically manufacture medium size parts require high accuracy such as gear housings, heat exchanger, connecting rods, and lever arms.
Lost Form Casting
Lost form casting offers similar benefits as lost wax casting, but avoiding complex process of making wax shell. It is relatively simple to make mold and allows recycling of sand. It is consisted of three stages
- White Mold Stage: Mold Foam into shape
- Yellow Mold Stage: Coating the Mold
- Black Mold Stage: Pour Liquid Metal, which takes place of the foam.
Vacuum Casting
Vacuum casting uses a plastic film to cover sand surface and uses vacuum to shape sand. It produces casting parts with better surface and dimensional accuracy. It is a greener method than traditional casting.
Our factory in Jiangsu China can cast steel or s.g. iron, from weight 10Kg to 3000kg. Please see the pictures below for samples of products.
Centrifugal casting
In this process molten metal is poured in the mold and allowed to solidify while the mold is rotating. Metal is poured into the center of the mold at its axis of rotation. Due to centrifugal force the liquid metal is thrown out towards the periphery.
Permanent mold
Permanent mold casting is a metal casting process that employs reusable molds (“permanent molds”), usually made from metal. The most common process uses gravity to fill the mold. However, gas pressure or a vacuum are also used.
Lost Wax Casting
Lost-wax casting (also called investment casting) is the process by which a duplicated metal sculpture (often silver, gold, brass or bronze) is cast from an original sculpture. Variations of the process include: “lost mold”, which recognizes that materials other than wax can be used (such as: tallow, resin, tar and textile) and “waste wax process” (or “waste mold casting”), because the mold is destroyed to remove the cast item.
Die Casting
The die casting process forces molten metal under high pressure into mold cavities (which are machined into dies). Most die castings are made from nonferrous metals, specifically zinc, copper, and aluminum-based alloys, but ferrous metal die castings are possible. The die casting method is especially suited for applications where many small to medium-sized parts are needed with good detail, a fine surface quality and dimensional consistency.
Most cast products require secondary machining processes immediately following the initial pour. Executing rough or precise machining workflows allows us to proactively identify internal casting defects prior to logistics and shipping. X-Pro possesses deep technical expertise matching the unique machining properties of diverse cast steels and specialized alloys. We economically machine components to meet rigorous IT6 to IT8 dimensional tolerance levels.
Furthermore, X-PRO LLC offers true single-source manufacturing. For example, following your casting and post-processing machining cycles, we provide custom surface treatments to deliver a fully finished, market-ready component.
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Powder Coating
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Spray painting
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Silk Screen Printing
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Hot-Dip Galvanizing
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Precision Polishing
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Uniform Anodizing
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How Can X-Pro Help With My Project?
X-Pro helps clients with one-time and ongoing project needs. Our specialties include 3D modeling, 3D design, CAD drafting, 3D animation, engineering and 3D renderings, 3D industrial design, prototype design, 3D printing design, mechanical design, architectural design, structural design, 3D interior design, and CAD landscaping design services.
Our CAD designers and drafting contractors work with AutoCAD, SolidWorks, Autodesk Inventor, Maya, 3ds Max, CATIA and many other types of software. Submit your project description and work with a pre-qualified 3D artist, CAD designer, drafter, 3D modeler, 3D animation or engineer specialized for your project needs.
The Project Flow
1. Tell us about your project
Describe your project, estimate the number of hours needed, the duration, and software requirements.
2. Pre-qualified expert freelancer
One of our engineers will contact you to discuss your project and gather more details.
3. Deposit & work
Agreement will need to be signed and payment deposit made in order to begin a project.
FAQ for your new project
Why X-Pro?
We connect you with the best designers in the business, and we offer the most comprehensive set of services for inventors you’ll find anywhere. We take the guesswork out of online design services, and let you focus on what’s important.
How do private projects work?
Simple. Just send us a project brief and we will provide you with a design quote from a pre-qualified designer for your project.
Who can see my project?
Private projects are entirely confidential. Only you and the designer that you will be working with will see your project description, file attachments and submitted work.
Do I own the designs & IP?
Yes. Our legally binding terms of service assign the ownership of intellectual property (IP) from the designer to the service buyer for any paid designs.
Do you offer manufacturing services?
Yes we do! We offer a range of manufacturing services, including 3D printing, rapid manufacturing and conventional injection molding.
How is a design project different from hourly services?
Design projects are limited-term projects with a concrete budget, based on an upfront quote from the CAD designer. Hourly services are for ongoing work that generally have an open work scope.
Will designers sign a NDA?
We’ve got this covered. Our legally binding terms of service covers freelancer non-disclosure. Freelancers on X-Pro have agreed to and are bound by the terms of non-disclosure that are outlined in our terms of service.