Neway Precision Works Ltd R&D Team

  Brief Overview of Casting Processes Casting processes are pivotal in custom manufacturing, offering a versatile means of creating complex and intricate metal components. Casting methods, such as die casting and sand casting, are indispensable in various industries, including Consumer Electronics, Telecommunication, Lighting Solutions, Power Tools, and Locking Systems. Die casting is a precision-oriented technique known for its high-precision capabilities with tolerances as tight as 0.1 mm. It involves injecting molten metal, often aluminum or zinc, into steel molds under high pressure, resulting in products characterized by superior surface finish and dimensional accuracy. On the other hand, sand casting , a more traditional approach, relies on sand molds to shape metal parts. While it may not match die casting's precision, sand casting excels in versatility, cost-effectiveness, and suitability for larger, more complex components. It applies in industries such as Lighting Soluti

Gravity casting, also known as permanent mold casting, can be ideal for manufacturing metal components for specific applications. This article will examine when gravity casting is the optimal choice over other casting methods or machining processes to meet project requirements. Critical factors like part geometry, production quantities, material options, quality needs, lead time, and cost will be analyzed. What is Gravity Casting? Gravity casting relies on the force of gravity to fill metal molds positioned below a pouring basin. Once the mold cavity is filled, the liquid metal solidifies into the desired shape. The mold remains stationary during the pouring and solidification process with no applied pressure. The critical advantage of gravity casting is its use of reusable metal molds, typically made from cast iron, steel, or aluminum alloys. It enables repeatable production of consistently dimensioned castings with good surface finish at a relatively low cost. Simple castings may onl

 Sand cores are a crucial component in the sand casting process . They create internal cavities and detailed features within metal castings that cannot be generated using only a two-piece mold. The core forms negative space within the casting that would otherwise be impossible. Sand cores achieve this by placing temporary placeholders of bonded sand into the mold cavity, which displace liquid metal when the mold is poured. This sand is later removed through a designed opening in the casting, leaving behind hollow internal geometry. Core Properties Sand cores must satisfy several essential requirements: - Permeability - The core sand needs sufficient venting to allow gases to escape during molten metal pouring. It prevents gas defects. - Collapsibility - Following solidification, the sand core must be removable from the casting through physical collapse or dissolution using water or other agents. - Refractoriness - Heat resistance is required so the core does not melt, fuse or chemicall

 Precision casting service refers to a group of metal casting processes capable of producing dimensionally accurate metal parts with tighter tolerances and better surface finishes than conventional casting methods. The tolerance standards achieved depend on the specific casting process used. This article mainly discusses the tolerance standards of precision casting services that Neway can provide and can be achieved, including die casting, sand casting, and investment casting. Investment Casting Tolerance Standards Investment casting service is considered one of the most precise casting processes, capable of tight tolerances down to ±0.005 in (±0.13mm) or even tighter for small castings under four in2. For larger castings, the typical tolerance range is ±0.015 in (±0.38mm) or ±0.5% to ±1% of the nominal dimension. The wax pattern used in investment casting can be formed to exact dimensions, creating an accurate mold cavity in the ceramic shell. The ceramic shell withstands the forces