castpro Expertise

CastPro’s Experience In Investment Casting

Initially CastPro’s experience in investment casting inherit from our group and Cummins, our group set up investment casting workshop since 1970s;

In 2006 a JV (Wuxi Vane Wheel)  between our group and Cummins was founded focusing on manufacturing the turbo-charger wheels using investment casting technology.

As a supplier in the auto industry, process control, and stable quality are the key factors, Wuxi Vane become a world leading supplier without a customer complaint in the past 16 years,

As a spin-off from Wuxi Vane, CastPro inherited those valuable experiences too, which become our advantages in manufacturing implant castings

Engineering Capabilities

Most of our engineering team members have more than 10 years’ experience in investment casting, and over 800 part numbers of implant castings for Orthopedic industry have been successfully developed by our team since 2018.

Our engineering capabilities are the key factor to the success of your project.

Engineering Capabilities
Solidification Simulation

1- Solidification Simulation

Our engineering team is equipped with cutting-edge software that can simulate the solidification process.

It helps our team avoid the potential risk from structure design and optimize the assembling way, hence making our products with fewer casting defects and more cost competitiveness.

2- Metallographic Analysis

Metallographic analysis is the routine work of our engineering team, by reviewing the metallographic structure of casting parts periodically, we can monitor the performance and quality of our products microscopically.

Metallographic analysis is also one of the general requirements from those world-leading Orthopedic companies.

Metallographic Analysis
Rapid Prototyping

3- Rapid Prototyping

To help our customer shorten the development cycle, 3D printing technology is applied to make wax patterns instead of making a new molding,

It makes prototype castings finished in as short as 15 days.

4- Reverse Engineering

Our engineering team is also equipped with cutting-edge 3D scanning system, which help our customer to build 3D model when they only have a sample, substantially improving their design progress;

It also helps us do dimension comparison between casting samples and the 3D models, to make sure our casting parts meet the dimension requirement of customers.

Reverse Engineering
Failure Analysis

5- Failure Analysis

Delivered over 700K pieces of implant castings, our engineering team has accumulated extensive experience in casting failure analysis, by applying FTA and DOE.

We find out the root causes of those defects such as cracks, porosity, pit, inclusion, etc. With those experiences our team keeps optimizing our tree structure design and process flow, leading to as low as 0.5% of defect rate of our implant castings.

Steps in Castpro's Production Process

Molding Development
Molding Development

After we confirmed the detailed specification and signed a contract with the Customer, the molding will be outsourced to the molding maker based on the molding specifications by CastPro.

Wax Injection
Wax Injection

The specific molding will be installed on the wax injection machine, the wax is injected into the molding under pressure, then a wax pattern is created and taken out from the molding after the wax is solidified.

Wax Assembling
Wax Assembling

A certain quantity of wax patterns are assembled on a runner system in which the melting alloy will flow, the assembled wax patterns are called a cluster or a tree.

Shell Making
Shell Making

A certain quantity of slurry layers (also called shell) will be coated on the cluster/tree and then wait to dry, the process needs to be carried out under a certain temperature and humidity.

De-Waxing
De-Waxing

The Cluster/Tree be loaded into the De-Waxing kettle to remove (melt out) the wax under high temperature and pressure, hence only the shell is left.

Shell Baking
Shell Baking

The shell is preheated at a high temperature before holding the melted alloy.

Pouring
Pouring

The melted alloy is poured into the shell.

Shell Knock Out
Shell Knock Out

After the alloy is solidified, the shell will be knocked out and the casting parts appear.

sandblasting
Sandblasting

Remove the residual shells on casting parts totally by sandblasting.

cut off
Cut-off

The casting parts be cut off from the cluster.

Surface Grinding
Surface Grinding

The gate will be ground by the robotic system, and the surface rags will be milled to smooth.

Heat Treatment
Heat Treatment

Heat treatment will be applied on casting parts based on the customer’s specifications.

FPI&X-Ray inspection
FPI

Each casting part will accept FPI (fluorescent penetrating inspection) based on customer’s specifications.

x-ray inspection
X-Ray Inspection

Each casting part will accept X-Ray inspection based on customer’s specifications.

Visual&Dimensional Inspection castpro
Visual&Dimensional Inspection

Each casting part will accept visual and dimensional inspection based on the customer’s specifications.

Package and Storage
Package and Storage

All the qualified casting parts will be packaged and put in storage, ready for delivery.

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