Zetwerk offers sand casting as a low-cost method for producing both small and large parts from a wide variety of ferrous and non-ferrous alloys. The sand casting process is exceptionally geared for producing large scale workpieces, and we have the resources that allow us to efficiently produce high volumes of parts. With its low tooling investment, sand casting is also ideal for short run work as well.
Zetwerk employs green-sand, no-bake, CO2 or shell molding processes to produce complex shapes from grey iron, ductile iron, carbon steel, alloy steel, and stainless steel grades, in addition to a wide variety of non-ferrous metals, such as aluminum, brass, bronze, copper and many more. All of these casting processes offer advantages and the process selection is based on program factors including annual volume, part size and weight, part geometry and complexity and surface finish requirements. Zetwerk can supply castings that range in weight from a few grams up to more than 50 tonnes.
Zetwerk has access to equipment that can accommodate a wide range of core requirements using both the shell process and CO2 process. A core is a preformed sand insert placed into the mold to shape the interior of a casting and are frequently used to create hollow sections or cavities in a casting, that are otherwise not possible to be shaped by the pattern. Our core making capabilities can meet all shapes, sizes and configurations.
We typically utilize production shell core boxes (cast iron or aluminum) but also offer CO2 cores for experimental and prototype work. New core tooling and mold patterns are created off of customer drawings and CNC machined to ensure precision and accuracy. Existing shell core tooling and mold patterns can easily be transferred and adapted to work by Zetwerk.
Sand casting typically yields parts with a rougher surface finish than other methods, but Zetwerk has the resources to proof machine or finish machine sand cast parts to improve the surface profile and achieve tight dimensional tolerances. Zetwerk also has the capability to perform any intermediate heat treatment required to achieve the desired mechanical properties and any surface treatment that may be required such as polishing, painting, coating or plating. Other services Zetwerk provides includes assembly work where we can provide the parts we produce put together in a sub-assembly and this service can include acquiring hardware or other components involved in the assembly.
Zetwerk also offers a wide range of in-house/third-party casting quality inspection and product testing services necessary to ascertain compliance to engineering specifications. These cover but are not limited to, chemical composition testing, tensile strength testing, hardness testing, impact testing, dye-penetrant testing, magnetic particle inspection and radiography inspection.
Zetwerk’s global sourcing solutions are practically unlimited in terms of casting alloys/materials, production capacities, part sizes and weights, secondary operations, surface finishes, assembly and services. How can we help you?