Custom Permanent Mold Casting Supplier | TFG USA
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Custom Permanent Mold Casting Supplier

Permanent mold casting, also known as gravity casting, is a process in which molten metal is poured into a metal mold made from steel or cast iron to create new metal pieces. The metal mold is called a permanent mold because it can be reused.

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The first step is to prep the permanent mold by heating it and applying a ceramic coating to ensure the part does not stick inside it. The mold is then assembled with two halves, and cores if required.

A molten usually non-ferrous metal is then poured into the mold from the top, filling the entire cavity. After the mold has been filled, the molten metal cools, solidifies, and is then removed from the move by opening the two halves.

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In the case of slush casting, the outside of the piece has cooled but the inside is still liquid. The inner liquid is poured out to create a hollow piece. If pouring molten metal will not produce a detailed enough piece, the molten metal can be forced in the mold using either low pressure or vacuum pressure.

No matter the method to get the molten metal into the mold, the last step is cleaning up the piece. Excess material from the pour site is trimmed away, leaving a completed metal piece.

The Advantages And Disadvantages Of Permanent Mold Casting

Permanent mold casting can be used for high production rates and you can reuse the molds many times. Complex shapes can be formed with low labor costs using highly automated processes. The finished pieces have a good surface finish and good dimensional accuracy.

Permanent mold casting also produces little waste. Disadvantages include a higher cost to create the metal molds and only non-ferrous metals can be used due to their low melting points unless a specialized graphite mold is created. Molds also have a short shelf life due to erosion and thermal fatigue.

Applications Of Permanent Mold Casting

Permanent mold casting is used heavily in the automotive industry to create parts like gears, castings, suspensions, fuel injection housings, and engine pistons. Aircraft parts are also often made via permanent mold casting.

Client Testimonials

Excellent
Based on 9 reviews
Alex Armstrong
Alex Armstrong
2023-12-15
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Steve was great to work with and was always available when needed.
Jon Ramsey
Jon Ramsey
2023-10-07
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Mike 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.
Nic Robinson
Nic Robinson
2023-10-05
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Steve 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.
Sean Connelly
Sean Connelly
2023-06-21
Trustindex verifies that the original source of the review is Google.
The 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!
Sher Stahl
Sher Stahl
2020-07-10
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The 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.
Marshall
Marshall
2020-06-30
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Excellent customer service and products!
Mae Winter
Mae Winter
2020-06-25
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Great parts, great prices and great people! Everything you want and need in a trusted supplier.
Dave Scillion
Dave Scillion
2020-06-24
Trustindex verifies that the original source of the review is Google.
Federal Group is a terrific supplier to work with. Quality parts at competitive pricing. Richard Jegla is great to work with there!

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