Balasen Lost Foam Casting
https://www.balasen.com/produc....ts/lost-foam-casting


The foam pattern, typically made from polystyrene, is coated with a refractory material and then buried in sand. When molten metal is poured into the mold, the foam vaporizes, leaving behind a cavity that is filled by the metal, thus forming the final cast part. As one of the leading lost foam casting companies, lost foam casting suppliers and lost foam casting manufacturers, we ensure precise pattern replication and high-quality surface finishes for complex parts.

It is similar to investment casting, except foam is used for the pattern instead of wax. This process takes advantage of the low boiling point of polymer foams to simplify the investment casting process by removing the need to melt the wax out of the mold. Many manufacturers turn to lost foam casting China solutions for their cost-effectiveness, scalability, and ability to produce intricate geometries with minimal machining.

Basic Introduction to Lost Foam Casting
EPC process, also known as full mold casting, is a new casting method that uses foamed plastics (such as EPS, STMMA or EPMMA) to make molds, and forms castings by pouring liquid metal. Lost foam casting is widely used in the production of various complex castings such as automotive parts, engineering machinery components, pipelines and valves, agricultural machinery components, etc.

Advantages of Lost Foam Casting
Lost foam casting has the following advantages:

1. High Precision:

Foam plastic models ensure accurate dimensions and smooth surfaces. Without parting lines and cores, it effectively reduces dimensional deviations and surface flaws, guaranteeing high-quality castings.

2. Design Flexibility:

Multiple parts can be integrated into one model for casting, optimizing part structures and reducing assembly work.

3. High Efficiency:

Eliminating complex procedures like mold removal and core setting shortens the production cycle, making it suitable for mass production.

Investment Casting (Lost Wax Casting) Manufacturer
https://www.balasen.com/produc....ts/investment-castin


As a precision casting factory, precision casting supplier and precision investment casting company, we have medium temperature wax and low-temperature wax precision casting processes, which can produce castings of various materials according to international material standards such as EN, DIN, BS, AISI, ASTM, JIS, etc. The casting size accuracy can reach ISO 8062 CT6, the casting surface roughness can reach Ra 1.6~Ra 3.2, the casting unit weight range is 0.09g to 120Kg, the maximum casting size is 1200mm × 800mm × 400mm, and the minimum casting wall thickness is 0.5mm.

Investment casting medical is a precision casting process suitable for producing high-precision, complex structured metal components. Its products are widely used in aerospace (turbine blades, engine parts), medical (orthopedic implants, surgical instruments), automotive (precision gears, sensor housings), energy (pump valve components), and art decoration fields. The technological advantage lies in the ability to form thin-walled, finely textured, and nearly net shaped parts, reducing subsequent processing. The materials include stainless steel, aluminum alloy, titanium alloy, high-temperature alloy, etc., meeting the requirements of high temperature resistance, corrosion resistance, and high strength. High precision investment casting products are known for their precise size and high surface finish, and are one of the core manufacturing technologies for complex metal parts in high-end manufacturing industries.

The Role of Investment Casting in Complex Metal Part Production
The role of investment casting in the production of complex metal parts:

High precision molding:

By replicating complex structures through wax molds, a tolerance of ± 0.1mm is achieved to meet the precision requirements of aerospace, medical and other fields.

Balasen Green Sand Casting
https://www.balasen.com/produc....ts/green-sand-castin


Aluminum green sand casting is a traditional process widely used in metal casting. Its core involves mixing clay as a binder with sand particles to create sand molds for pouring molten metal. Below is a detailed summary of its key parameters, advantages, classifications, and suitable products.

We have an automatic production line for horizontal tide mold sand in Dongjiu, Japan, which can provide 5-100kg ductile iron and gray iron castings, 100 boxes/hour, with an annual production capacity of over 16000 tons of castings. Mainly producing ductile iron parts (main grades QT400, QT450, QT500, QT600, QT700, etc.), including automotive parts, fire hydrant series, valve series, flange series, pipeline series, mechanical series and others, which can achieve all processes from casting to processing

Specifications of Green Sand Cast Iron Casting
Key Parameters of Green Sand Casting

1. Sand Mixture Ratio

- Clay content: Typically 8-12% (by mass), with clay serving as the binder.

- Sand particles: Mainly silica sand (80-90% by mass), with particle size controlled (50-100 mesh) to improve fluidity.

- Moisture: 4-6% (affects mold strength and permeability).

2. Green Compression Strength

- Mold compression strength: 0.1-0.3 MPa, ensuring the mold does not deform during handling and pouring.

3. Permeability

- Standard value: 80-150 (permeability units), ensuring gases are smoothly discharged during pouring.

4. Compactness Rate

- 35-45%, reflecting the degree of mold compaction, which affects strength and surface quality.

5. Mold Hardness

- Green sand hardness: 70-90 (Shore hardness scale), requiring uniform compaction.

Custom Metal Forging Process Company
https://www.balasen.com/products/forging/


Forging shapes metals through plastic deformation (hot forging/warm forging/cold forging), endowing them with high strength, toughness, fatigue resistance, and a dense microstructure, suitable for critical load-bearing components. The materials include carbon steel, alloy steel, titanium alloy, etc., and the processes include free forging, die forging, and precision forging. Core products such as automotive crankshafts, aviation engine blades, oil and gas valves, and heavy-duty gears have high load-bearing and impact resistance characteristics. Advantages: Eliminating casting defects and improving mechanical performance; Batch production costs are controllable and suitable for harsh working conditions (high temperature/high pressure). Quality control relies on non-destructive testing (UT/RT) and metallographic analysis, which are one of the core processes in high-end equipment manufacturing.

The existing equipment can meet the needs of various types of free forging and ring forging in metal forming products, and has factory certification certificates from 8 major ship class societies worldwide, API20A qualification certificates from the United States, API6A qualification certificates, APIQ1 system certificates, TPG NDT certification certificates, TPG heat treatment certification certificates, EU PED certification certificates, etc.

The materials we can produce are:

Carbon Steel: A105N, LF2, A694 F60, F65 etc.

Austenitic SS: ASTM A182 F316/F316L F304/F304L etc.

Duplex SS: ASTM F51, F60, F53, F55 etc.

The weight of forgings can reach 40-650kg; Maximum diameter 1600mm

How to Improve the Durability of CNC Machine Tool Parts Through Forging
The core mechanism for improving the durability of CNC machine tool parts through forging can be divided into the following four aspects:

Grain refinement enhances fatigue resistance

Forging densifies metal grains and eliminates casting defects such as porosity and shrinkage through hot deformation, improving the uniformity of the microstructure of the parts, increasing fatigue strength by 30% -50%, and extending the high-frequency impact resistance life of key components such as gears and spindles.