Gensun provides casting services including precision investment casting, die casting, metal injection molding. And we offer a variety of services to ensure the quality and longevity of all of our casting products, such as machining, heat treatment, surface finishing and assembly.
Precision Investment Casting
Precision investment casting is the process of creating investment castings with the highest level of detail and customization. The precise nature of the casting enables the manufacturer to create even the most detailed and delicate shapes through the casting process, which is unusual for most casting processes.
Benefits of Precision Investment Casting
When you switch to precision investment casting, you will incur the following production benefits:
Affordable: You can save up to 50 percent on production costs by switching to a casting method. Casting is an affordable process that requires fewer tools and operators to become successful. While some materials were too delicate or detailed in the past for casting, precision casting makes it a possibility for most metal shapes.
Higher details: Precision casting gives each casted piece a high level of detail. The precise nature of the casting process and the molds themselves make the process compatible with nearly any metal piece no matter how delicate.
Reduced material and labor costs: In precision casting, few materials are wasted, which make material costs lower. Fewer people are required to complete the process, which drives labor costs lower as well.
Material variety: Metal casting can work with a variety of materials, including nickel, cobalt, base alloys, carbon, aluminum, stainless steel, and many others
Die casting is a manufacturing process that can produce geometrically complex metal parts through the use of reusable molds, called dies. The die casting process involves the use of a furnace, metal, die casting machine, and die. The metal, typically a non-ferrous alloy such as aluminum or zinc, is melted in the furnace and then injected into the dies in the die casting machine.
Advantages of Die Casting
○Excellent dimensional accuracy
○Smooth cast surfaces
○Thinner walls can be cast as compared to sand and permanent mold casting
○Inserts can be cast-in
○Reduces or eliminates secondary machining operations
○Rapid production rates
○Casting tensile strength as high as 415 MPa (60 ksi)
Metal Injection Molding (MIM)
Metal injection molding offers a manufacturing capability for producing complex shapes in large quantities. The process utilizes fine metal powders which are custom formulated with a binder into a feedstock which is granulated and then fed into a cavity (or multiple cavities) of a conventional injection molding machine. After the “green” component is removed, most of the binder is extracted by thermal or solvent processing and the rest is removed as the component is sintered (solid-state diffused) in a controlled-atmosphere furnace.
The metal injection molding (MIM) process offers the following advantages:
○Cost-effective manufacture of high volume complex parts
○Reduced production time compared with investment casting
○Net-shape manufacture with minimal material waste
○Mechanical properties superior to castings and other PM parts reflecting fine particle size and high sintered density
○Properties equivalent to wrought alloys
○Wide range of pre-alloys and master alloys available
○Minimum of finishing operations