Aluminum
Gravity Casting
Our primary process. Automated permanent-mold gravity casting with A356 and ZL114 alloys. Parts up to 1.2 m, T6 heat treatable, AI-monitored production.
Why Gravity Casting
6 Reasons Engineers Choose
Gravity Casting
Superior Mechanical Properties
Gravity casting produces a denser, lower-porosity microstructure than die casting. Combined with T6 heat treatment, A356 parts achieve 230–310 MPa UTS — ideal for structural and safety-critical applications.
Large Part Capability
Our process accommodates parts up to 1.2 m in maximum dimension. We have active production cases including intake manifolds at 1.2m × 0.5m — a capability few gravity casting facilities can match.
AI-Optimized Scheduling
Proprietary Claude AI model monitors fill rates, temperature curves, and solidification data in real time. Anomalies are detected before they become defects. Schedule optimization reduces idle time and improves throughput.
Cost-Effective Tooling
Gravity casting molds are 40–60% less expensive than high-pressure die casting tooling. Lower upfront investment with shorter 45-day tooling lead time.
T6 Heat Treatable
Unlike die casting alloys, A356 and ZL114 are fully heat treatable. T6 treatment (solution + aging) significantly enhances tensile strength, yield strength, and fatigue resistance.
Pressure-Tight Castings
Low porosity gravity cast parts pass pressure tests for pneumatic and hydraulic applications. Suitable for valve bodies, pump housings, and other pressure-critical components.
Our Process
From Design to
Finished Part
Mold Design & Tooling
DFM review, gating system design, thermal analysis. Tooling fabricated from H13 tool steel.
Melt & Alloy Control
Oxford spectrometer verifies alloy composition before each pour. Degassing treatment for porosity control.
Automated Gravity Pour
Automated tilt-pour machines maintain consistent fill speed and temperature. AI monitors every pour cycle.
Controlled Solidification
Cooling rates optimized per geometry. Directional solidification for critical sections.
Heat Treatment
In-house T5/T6 treatment. Temperature-controlled furnaces, quench tanks, aging ovens.
Machining & Finishing
CNC machining to final dimensions. Deburring, shot blasting, surface treatment as required.
Inspection & CMM
X-ray NDT, CMM dimensional check, mechanical property testing. Full traceability per TS16949.
Gravity Casting vs Die Casting
When to choose gravity casting — and when not to.
| Factor | Gravity Casting ✓ | Die Casting |
|---|---|---|
| Mechanical properties | Excellent (T6 treatable) | Good |
| Porosity | Low | Higher (trapped gas) |
| Part size | Up to 1.2 m | Typically < 600 mm |
| Tooling cost | Lower ($5k–$30k) | Higher ($20k–$100k+) |
| Tooling lead time | 45 days | 60–90 days |
| Volume | Medium to high | High volume preferred |
| Wall thickness | ≥ 3.5 mm | ≥ 1.5 mm |
| Heat treatability | Yes (A356/ZL114) | Limited |
Ready to Discuss Your Part?
Send us your drawings or describe your requirements. Our engineers will assess feasibility within 24 hours.
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