Making sure we possess the best technology on the market is an integral part of our corporate strategy.
ENGINEERING AND CO-DESIGN
Through continuous investments in engineering and technological development, Ironcastings has become a technical partner able to support OEM customers from the earliest stages of component development.
We collaborate with customers in co-design and industrialization activities, with the objective of developing components optimized for the casting process and economically sustainable for serial production.
Our engineering department supports customers throughout the entire product development cycle through:
- technical feasibility analysis
- casting-oriented design optimization
- casting and solidification simulation using ProCAST software
- tooling design and industrialization
- reverse engineering through 3D scanning
Through re-engineering activities, we also support the optimization of existing components in order to improve performance and manufacturability through:
- weight optimization
- cost reduction
- improvement of metallurgical quality
Early engineering involvement allows us to reduce technical risks, shorten development times and lower industrialization costs, providing reliable solutions fully compatible with OEM serial production requirements.
MOLDING
Production is carried out through an automatic Heinrich Wagner Sinto molding line with SEIATSU technology, with flask dimensions of 1100 × 900 × 400 + 350 mm and a capacity of up to 120 molds per hour.
The SEIATSU technology ensures uniform sand compaction, delivering excellent surface quality and dimensional stability even for complex cast components.
The molding process is supported by a fully automated sand preparation system, managed through a Green Sand Control (GSC) system that continuously monitors and adjusts key sand parameters to guarantee process stability and consistent quality.
The core assembly process allows the production of complex internal geometries and functional cavities required for OEM components.
MELTING PROCESS
The melting department includes:
- 3 induction melting furnaces type C55 MF – 5 MW with IGBT technology
- 1 automatic pouring furnace CAP (Coreless Automatic Press Pouring) – 8 tons
The plant currently produces up to 100 tons of liquid iron per day.
The molten metal is continuously monitored through:
- spectrometric chemical analysis
- thermal analysis
- control of solidification curves
The entire melting process is supervised by a centralized process laboratory, which ensures continuous monitoring of metallurgical parameters and supports stable and repeatable production conditions.
After pouring, castings are transferred to a controlled cooling area, where they remain until fully cooled before proceeding to subsequent processing steps.
FINISHING, INSPECTION AND TRACEABILITY
After shake-out, castings are processed in a DISA CT4 belt shot blasting machine, where surfaces are cleaned by shot blasting before the removal of risers.
Depending on customer specifications, components can then undergo additional finishing processes including:
- fettling
- heat treatment
- surface treatment and coating
- machining
The entire production process is managed through a MES system, enabling full digital traceability of castings across all production stages.
The quality system includes complete metallurgical, mechanical and dimensional inspections such as:
Chemical analysis: ARL 3460 spectrometer – 18 elements
Mechanical testing : tensile and hardness testing (Galdabini and Heckert machines)
Dimensional inspection: traditional measuring instruments, 3D optical scanning and ZEISS ScanBox
Metallographic and non-destructive testing: microstructural analysis and ultrasonic testing with Krautkramer equipment
Production and quality data are also monitored through Statistical Process Control (SPC) to ensure production stability and repeatability.All inspection data are reported in the EN 10204 – 3.1 inspection certificate. The production process is managed according to industrial sustainability principles, including energy consumption monitoring and continuous optimization of production resources.
