Custom Investment Casting Manufacturing Company
The Federal Group USA provides high-quality investment casting services for a variety of industries. The investment casting process allows for very precise metal features that can produce parts with smooth surfaces. This process can create near-net-shape parts with outstanding dimensional accuracy.
Request a QuoteAdvanced Technology
Automated robotic molding machines and specialized shell making equipment
Versatile Material Options
Stainless steel, aluminum, brass, copper, magnesium, and more
Proven Experience
Manufacturing custom investment castings since 1980
Quality Assurance
Non-destructive testing like radiography and dye penetrant testing
Case Study
When a client required a machined casting with ±0.0001″ tolerances, The Federal Group engineered a precision investment casting process to meet the demand. Through optimized tooling design, CNC machining, and controlled process validation, we achieved exceptional dimensional accuracy and repeatability.
Read the case study by clicking the link below.
Industries We Work With
As a leading investment casting manufacturer, The Federal Group proudly serves a variety of industries with precision investment casting services. We meet the specific needs of each sector with tailored investment casting solutions, ensuring exceptional performance and reliability with every component we manufacture. From medical equipment to the marine industry, our investment casting processes ensure that each part meets the highest safety and quality standards in every industry we serve.
Medical Equipment
In the medical industry, precision casting can be a matter of life and death. Our custom investment casting procedures are designed to deliver exceptional accuracy and consistency, allowing us to produce precise biocompatible components with exceptionally high tolerances. Whether you need surgical tools, implants, or diagnostic devices, every part we make provides the durability and reliability required by the medical field.
Oil and Gas
Our investment casting process is versatile, perfect for industries like the oil and gas sector where special alloys and smart metals are needed to withstand extreme conditions. We use modern investment casting techniques and surface treatments to produce complex components like valves and pumps that can withstand high temperatures and corrosive environments.
Marine and Shipbuilding
Investment casting plays a vital role when it comes to the marine and shipbuilding industry. Parts and equipment in this sector must be able to endure long-term exposure to highly corrosive salt water and extreme temperatures. Investment casting is the ideal solution for manufacturing corrosion-resistant components like propellers, engine parts, and marine hardware.
Equipment
Image above: Disamatic Automated Investment Casting Machine.
Having the right equipment for the investment casting process is essential. At The Federal Group USA, we use state-of-the-art technology to ensure the success of every project. Below is just some of the investment casting equipment that we leverage:
- Specialized shell-making equipment
- Highly automated robotic molding machines
- Horizontal vacuum precision furnace
- Vertical vacuum precision furnace
- High-pressure gas quenching vacuum furnace
- Medium to high-volume production
- Reliable quality assurance equipment
Automation
We use the latest wax processing technology. Our semi-automatic wax injection machines allow us to make wax patterns quickly and reduce the time it takes to finish the project.
Our dewaxing machines quickly melt the pattern without cracking the ceramic shell. We use specialized equipment to pour the molten metal without creating air pockets, minimizing the risk of defects. A thorough quality assurance process follows.
Materials
Pictured above: Raw billets / ingots used for investment casting.
We can work with the following materials and more:
Carbon steel and most steel alloys, brass, bronze, copper, aluminum, and Stainless Steels including Duplex 2205, 2507, and others.
300 Series
- Superior corrosion resistance
- Non-magnetic
- Scratch-resistant
400 Series
- Magnetic
- Greater strength than carbon steel.
- Suitable where thinner materials/reduced weight are needed
Aluminum
- Investment casting of aluminum makes it possible to create parts with complex shapes more quickly.
- This process is also more flexible when using different types of alloys.
- Parts made through this process have tighter dimensional tolerances and better surface finishes.
- This method requires less machining and processing.
Brass/Bronze
- Excellent machinability
- Corrosion resistance
- Aesthetics
Copper-Based Alloys
- Corrosion resistance
- Ductility
- Conductivity—thermal & electrical
- The price of copper can fluctuate significantly with the market. So, it’s essential to reduce waste when producing complex components of copper.
- Investment casting is an excellent way to minimize this waste.
Duplex 2207
- A super duplex stainless steel with 25% chromium, 4% molybdenum, and 7% nickel alloy.
- They are designed for applications that require exceptional strength and corrosion resistance.
Duplex 2205
- A two-phase, ferritic, austenitic 22% chromium, 3% molybdenum, 5 to 6% nickel alloy.
- Duplex 2205 is the most widely used duplex stainless steel grade and is characterized by high yield strengths.
- It has good fatigue strength and demonstrates outstanding resistance to stress corrosion cracking, crevice, pitting, erosion, and general corrosion in severe environments.
Grey, Ductile, and White Iron
- Tool steels, mild steel, alloy steels, etc.
- Used for a variety of purposes for ease of machinability, ductility, or compressive strength
Magnesium
- Excellent dimensional stability
- A good structural material
- Ability to produce fine detail
Investment Castings vs. Sand Castings: Which Should I Choose?
Investment casting is not the only casting service that we provide. We also offer:
- Stainless steel investment casting
- Sand casting
- Rapid prototype casting
- Centrifugal casting
- Lost foam casting
- Permanent mold casting
- Die casting
The investment casting process is typically used to produce parts that need to be very precise. This casting process makes it possible to have thin walls and complex internal cavities.
The investment casting process provides you with finer details and a smoother surface finish than other casting techniques.
For example, the sand casting process uses a mixture of sand and clay to create a mold around a pattern of the final product. The mixture is more porous than the wax pattern used for investment casting, this means sand casting cannot create as intricate parts.
Why Choose TFG USA Investment Casting Services?
Our casting process yields highly intricate and accurate parts with tight tolerances for medical, marine, agricultural and beyond.
Whether you’re exploring options for a new product or you have an existing product that you’d like to put into production, The Federal Group USA can help you with your next investment casting project. We’ve provided high-quality manufacturing services since 1980.
Contact us today to learn more.
Client Testimonials
Trustindex verifies that the original source of the review is Google.
Jonathon Lanham2025-09-26Mike Allen and The Federal Group have been an absolute pleasure to work with. From the first day we reached out to them they responded punctually and professionally and helped us with every step of the process. We came to them with a budget conscious challenge and they delivered above and beyond a fitting and accurate solution. A quality finished part that has improved the overall quality of our product, and that's what really counts. Thank you to The Federal Group!Trustindex verifies that the original source of the review is Google.Sean Brockhouse2025-04-20Sandor Holzer has gone above and beyond helping us to get another part ramped up for production, creative getting samples ahead of schedule so we could meet tight timelines. Outstanding customer service!!Trustindex verifies that the original source of the review is Google.Melissa Quiroz2024-08-09Good company, knowledgeable staff, product was exactly what i asked for. Got me out of a jam!Trustindex verifies that the original source of the review is Google.Alex Armstrong2023-12-15Steve was great to work with and was always available when needed.Trustindex verifies that the original source of the review is Google.Jon Ramsey2023-10-07Mike at TFG was tenative to our supply needs and an immense help! Took on a project that was quite large and daunting, only to be resilient through the task challenges. In conclusion, everything was completed successfully and a huge success. Would recommend and I plan to use them for future projects. Thanks again Mike and TFG team.Trustindex verifies that the original source of the review is Google.Nic Robinson2023-10-05Steve Bogdanovich has been critical to our team meeting deadlines with a quality product. The communication and customer service is top notch. We know we can rely on Steve and The Federal Group team to get us a quality product and in a timely manner. We've sent all of our casted parts through them because we know we will get the best service, and they keep us informed through every step in the process.Trustindex verifies that the original source of the review is Google.Sean Connelly2023-06-21The Federal Group was great to work with. Steve was very professional and diligent in providing good advice/feedback as well as following up with me. Look forward to working with them in the future as well!Trustindex verifies that the original source of the review is Google.Sher Stahl2020-07-10The Federal Group is a top-notch supplier of ours. They take quality very seriously and strive to ensure we have exactly what we want and when we need it. Communication is excellent. Service is excellent. I have worked with this supplier directly for better than 7 years now, and still considered one of my best suppliers. We've recently expanded our product line with this company and are excited to partner on this line and on future projects. Words cannot express how grateful I am to have such a responsive company, and rep, Richard, to work with. I highly recommend this supplier.Trustindex verifies that the original source of the review is Google.Marshall2020-06-30Excellent customer service and products!
