Metal investment casting is a manufacturing process that has been around for centuries. It involves pouring molten metal into a mold, which is created by using a wax pattern. The wax pattern is then melted away, leaving behind a hollow cavity that is filled with molten metal. Investment casting is known for producing high-quality, complex parts with tight tolerances.
In the United States, there are many metal investment casting manufacturers that offer a wide range of services. These companies specialize in producing castings for various industries, including aerospace, medical, industrial, and power. With so many options available, it can be difficult to know which companies are the best. This article will provide a list of the top 10 metal investment casting manufacturers in the USA.
Investment casting is a complex process that requires a high level of expertise and precision. The companies on this list have a proven track record of producing high-quality castings for a variety of industries. From small prototype parts to large-scale production runs, these companies have the capabilities to meet the needs of their customers. Whether you are looking for a company that specializes in a specific type of metal or a company that offers a wide range of services, this list has something for everyone.
Top 10 Metal Investment Casting Manufacturers in USA
1. Impro Industries USA
Impro Industries USA, Inc. is a global leader in the casting production of a wide range of metal alloys for applications in the automotive, aerospace, hydraulic, heavy-duty, recreational, power, and medical sectors. With headquarters in Diamond Bar, California, Impro Industries USA has over 20 years of experience in precision investment casting and has an annual sales revenue of over $100 million. The company is known for its high-quality, cost-effective, and innovative casting solutions and has a strong reputation as one of the top casting suppliers in the USA.
2. MetalTek International
MetalTek International is a leading metal casting manufacturer with over 100 years of experience in the industry. The company offers investment casting solutions in a wide range of alloys, including stainless steel, carbon steel, and nickel-based alloys, and has an annual sales revenue of over $500 million. MetalTek International is known for its advanced casting technologies, including rapid prototyping and 3D printing, and has a strong reputation as one of the top casting manufacturers in the USA.
3. Sigma OEM
Sigma OEM is a leading investment casting company that specializes in the production of high-quality, complex castings for a wide range of industries, including aerospace, defense, medical, and energy. The company has an annual sales revenue of over $50 million and is known for its advanced casting technologies, including vacuum casting and ceramic shell casting. Sigma OEM is a trusted supplier of precision investment castings and has a strong reputation for quality and reliability.
4. Precision Castparts Corp
Precision Castparts Corp is a leading manufacturer of investment castings, forged metals, fastening systems, and more. The company produces specialty alloys along with cast parts and serves the aerospace, medical, industrial, and power markets. Precision Castparts Corp has an annual sales revenue of over $10 billion and is known for its advanced casting technologies, including rapid prototyping and 3D printing. The company has a strong reputation as one of the top casting suppliers in the USA.
5. American Casting Company
American Casting Company is a leading investment casting supplier that specializes in the production of high-quality, complex castings for a wide range of industries, including aerospace, defense, medical, and energy. The company has an annual sales revenue of over $20 million and is known for its advanced casting technologies, including ceramic shell casting and lost wax casting. American Casting Company is a trusted supplier of precision investment castings and has a strong reputation for quality and reliability.
6. Ferralloy, Inc.
Ferralloy, Inc. is a leading supplier of investment castings and other metalworking products for a wide range of industries, including aerospace, defense, medical, and energy. The company has an annual sales revenue of over $50 million and is known for its advanced casting technologies, including vacuum casting and lost wax casting. Ferralloy, Inc. is a trusted supplier of precision investment castings and has a strong reputation for quality and reliability.
7. Barron Industries
Barron Industries is a leading investment casting company that custom manufactures investment cast parts, including precision and prototype parts. The company offers castings in aluminum, steels, cobalt, nickel, and special investment casting alloys, is AS9100 and ISO 9001 certified, as well as ITAR registered and Nadcap accredited. Barron Industries has an annual sales revenue of over $20 million and is known for its high-quality, cost-effective, and innovative casting solutions. The company has a strong reputation as one of the top casting suppliers in the USA.
8. Waupaca Foundry
Waupaca Foundry is a leading manufacturer of gray and ductile iron castings for a wide range of industries, including automotive, agriculture, and construction. The company has an annual sales revenue of over $1 billion and is known for its advanced casting technologies, including green sand casting and lost foam casting. Waupaca Foundry is a trusted supplier of high-quality castings and has a strong reputation for quality and reliability.
9. Eastern Metal Supply
Eastern Metal Supply is a leading supplier of aluminum extrusions, sheet, plate, and coil products for a wide range of industries, including construction, transportation, and marine. The company has an annual sales revenue of over $500 million and is known for its high-quality products and exceptional customer service. Eastern Metal Supply is a trusted supplier of high-quality metal products and has a strong reputation for its international customers.
Types of Casting Processes
Investment casting is a metal forming process that involves the production of complex and intricate parts with high accuracy and surface finish. There are several types of casting processes that are commonly used in the metal casting industry. These processes include:
1. Sand Casting
Sand casting is a process that involves the use of sand molds to create metal parts. The process involves the creation of a pattern that is used to create the sand mold. The pattern is made of wood, plastic, or metal and is used to create a negative impression in the sand. Molten metal is then poured into the mold and left to cool and solidify. The sand is then removed to reveal the final part.
2. Plaster Mold Casting
Plaster mold casting is a process that involves the use of plaster molds to create metal parts. The process involves the creation of a pattern that is used to create the plaster mold. The pattern is made of wood, plastic, or metal and is used to create a positive impression in the plaster. Molten metal is then poured into the mold and left to cool and solidify. The plaster is then removed to reveal the final part.
3. Continuous Casting
Continuous casting is a process that involves the continuous pouring of molten metal into a mold. The mold is cooled and solidified as the metal is poured into it. The process is used to create long and continuous shapes such as pipes, tubes, and bars.
4. Lost-Wax Casting
Lost-wax casting, also known as investment casting, is a process that involves the creation of a wax mold of the final part. The wax mold is then coated with a ceramic material and left to dry. The ceramic shell is then heated to melt the wax and harden the ceramic. Molten metal is then poured into the ceramic shell and left to cool and solidify. The ceramic shell is then removed to reveal the final part.
5. Centrifugal Casting
Centrifugal casting is a process that involves the use of centrifugal force to create metal parts. The process involves the pouring of molten metal into a spinning mold. The centrifugal force distributes the molten metal evenly throughout the mold, creating a part with a uniform density and surface finish.
Each of these casting processes has its own advantages and disadvantages. The choice of casting process depends on the requirements of the final part, such as size, shape, complexity, and material.
Applications of Investment Casting
Investment casting is a versatile manufacturing process that can produce complex and precise metal parts with a high degree of accuracy and repeatability. Investment casting has a wide range of applications in various industries, including aerospace, medical, industrial, defense, electronics, non-destructive testing, and jewelry.
1. Aerospace
The aerospace industry is one of the major users of investment casting. Investment casting is widely used to produce complex and critical components for aircraft engines, such as turbine blades, vanes, and impellers. The investment casting process allows for the production of parts with intricate geometries and thin walls, which are difficult to achieve with other manufacturing methods. Investment casting also offers excellent surface finish and dimensional accuracy, which is crucial for aerospace applications.
2. Medical
The medical industry also relies on investment casting to produce a variety of components, including surgical instruments, implants, and prosthetics. Investment casting is an ideal manufacturing process for medical applications because it allows for the production of parts with complex shapes and contours, which are often required for implants and prosthetics. Investment casting also offers excellent surface finish, which is important for medical applications where cleanliness and biocompatibility are critical.
3. Industrial
The industrial sector uses investment casting to produce a wide range of components, including valves, pumps, and gears. Investment casting is well-suited for industrial applications because it allows for the production of parts with high precision and repeatability. Investment casting also offers excellent surface finish, which is important for components that require tight sealing or low friction.
4. Defense
The defense industry uses investment casting to produce a variety of components, including missile and rocket parts, gun components, and armor components. Investment casting is an ideal manufacturing process for defense applications because it allows for the production of parts with complex geometries and tight tolerances. Investment casting also offers excellent mechanical properties, which is important for components that require high strength and durability.
5. Electronics
The electronics industry uses investment casting to produce a variety of components, including housings, connectors, and heat sinks. Investment casting is well-suited for electronic applications because it allows for the production of parts with high precision and tight tolerances. Investment casting also offers excellent surface finish, which is important for components that require good electrical conductivity and thermal management.
6. Jewelry
Investment casting is widely used in the jewelry industry to produce intricate and detailed pieces. Investment casting allows for the production of parts with high precision and excellent surface finish, which is important for jewelry applications where aesthetics and quality are critical. Investment casting also allows for the production of parts with a wide range of materials, including gold, silver, and platinum.
Materials Used in Investment Casting
Investment casting is a versatile process that can be used with a variety of materials to produce high-quality castings with excellent surface finishes and dimensional accuracy. Here are some of the most commonly used materials in investment casting:
1. Aluminum
Aluminum is a lightweight, corrosion-resistant material that is commonly used in investment casting. It is ideal for applications that require high strength-to-weight ratios, such as aerospace and automotive components. Aluminum investment castings can also be used in the production of consumer goods, medical equipment, and industrial machinery.
2. Bronze
Bronze is a copper alloy that is widely used in investment casting due to its excellent strength, durability, and corrosion resistance. It is commonly used in the production of decorative items, as well as marine and architectural hardware. Bronze investment castings can also be used in the production of musical instruments, jewelry, and sculptures.
3. Cobalt
Cobalt is a hard, corrosion-resistant material that is commonly used in investment casting for its excellent wear resistance and high-temperature properties. It is ideal for applications that require high strength and durability, such as aerospace and industrial machinery components. Cobalt investment castings can also be used in the production of medical implants and prosthetics.
4. Stainless Steels
Stainless steels are a family of corrosion-resistant steels that are widely used in investment casting due to their excellent strength, durability, and resistance to high temperatures and corrosive environments. They are commonly used in the production of industrial machinery, automotive components, and medical equipment. Stainless steel investment castings can also be used in the production of consumer goods, such as kitchen appliances and bathroom fixtures.
Notable Investment Casting Manufacturers by State
Ohio
Ohio is home to several notable investment casting manufacturers, including the Precision Castparts Corp. The company produces specialty alloys along with cast parts and serves the aerospace, medical, industrial, and power markets. Another prominent investment casting manufacturer in Ohio is the Ohio Valley Manufacturing Company, which specializes in producing high-quality investment castings for a variety of industries, including aerospace, defense, and medical.
New Jersey
New Jersey is home to several investment casting manufacturers, including Signicast Investment Castings, which produces complex and high-quality investment castings for a variety of industries, including aerospace, defense, and medical. Another notable investment casting manufacturer in New Jersey is the Atlantic Casting & Engineering Corp., which specializes in producing investment castings in a variety of materials, including stainless steel, aluminum, and brass.
Tennessee
Tennessee is home to several investment casting manufacturers, including the Consolidated Precision Products Corp., which produces high-quality investment castings for the aerospace, defense, and industrial markets. Another notable investment casting manufacturer in Tennessee is the American Casting Company, which specializes in producing investment castings in a variety of materials, including stainless steel, aluminum, and bronze.
Indiana
Indiana is home to several investment casting manufacturers, including the Indiana Investment Castings Corp., which specializes in producing high-quality investment castings for the aerospace, defense, and medical industries. Another notable investment casting manufacturer in Indiana is the Signicast Investment Castings, which produces complex and high-quality investment castings for a variety of industries, including aerospace, defense, and medical.
Emerging Technologies in Investment Casting
Investment casting is an ancient manufacturing process, but it is still evolving with the emergence of new technologies. These technologies are improving the precision, efficiency, and cost-effectiveness of investment casting. In this section, we will discuss three of the most promising emerging technologies in investment casting: 3D printing, injection tooling, and scale factor.
3D Printing
3D printing, also known as additive manufacturing, is a revolutionary technology that is transforming many industries, including investment casting. 3D printing enables investment casting manufacturers to create complex geometries with high precision and accuracy. It also reduces the lead time and cost of investment casting by eliminating the need for tooling and reducing the material waste.
With 3D printing, investment casting manufacturers can create wax patterns, ceramic shells, and even metal parts directly from a digital model. This technology allows investment casting manufacturers to produce prototypes and small batches of parts quickly and cost-effectively. However, 3D printing has some limitations, such as the size and resolution of the printer, the quality of the material, and the post-processing requirements.
Injection Tooling
Injection tooling is another emerging technology that is improving the efficiency and accuracy of investment casting. Injection tooling is a process of injecting wax or plastic into a mold to create a wax pattern. This technology enables investment casting manufacturers to produce high-quality wax patterns with consistent dimensions and minimal defects.
Injection tooling reduces the lead time and cost of investment casting by eliminating the need for manual wax pattern production and reducing the material waste. It also improves the quality and consistency of the wax patterns, which translates into better casting quality and reduced scrap rate. However, injection tooling requires a significant upfront investment in equipment and tooling, and it has some limitations, such as the complexity and size of the part and the type of material.
Scale Factor
Scale factor is a technology that is improving the accuracy and repeatability of investment casting by accounting for the shrinkage of the metal during solidification. Scale factor is a ratio that represents the difference between the dimensions of the wax pattern and the final dimensions of the cast part. By applying the scale factor, investment casting manufacturers can compensate for the shrinkage and produce parts with accurate dimensions and tolerances.
Scale factor is particularly useful for investment casting of large and complex parts, where the shrinkage can cause significant dimensional deviations. Scale factor also enables investment casting manufacturers to produce parts with tight tolerances and minimize the post-processing requirements. However, scale factor requires accurate measurement and calculation of the shrinkage, which can be challenging for some materials and geometries.