DESIGN ENGINEERING AND MANUFACTURING SOLUTIONS

Design Engineering and Manufacturing Solutions (DEMS) is the One-Stop service offered at Best Cast that involves the study and selection of design methodologies, engineering materials, manufacturing processes and quality control used in the design, development and manufacture of engineered components.

Best Cast, Our expertise lies in delivering superior quality products to our customers at the most competitive prices. We deploy a diverse array of software programmes to develop and test components based on customer specifications. Our company provides end-to-end solutions that encompass the Design phase, Rapid prototyping, in addition to Manufacturing of finished goods.

Best Cast has worked with more than 120 pre-approved suppliers internationally to guarantee the highest quality and fastest turnaround times. We collaborate extensively with both customers and suppliers to determine the most efficient means to manufacture each component This includes gathering detailed project information, including part specifications, material properties, production volumes, and budget considerations. In terms of project management at Best Cast, as well as our global supplier footprint, we bring technical competency and reliability to every project while delivering components of any specification and process.

NEW PRODUCT DEVELOPMENT

Best Cast adheres to IATF standards and Quality Management Systems (QMS) that follow the AIAG Key Elements, which include Failure Mode and Effects Analysis (FMEA), Statistical Process Control (SPC), Measurement Systems Analysis (MSA), and Production Part Approval Process (PPAP). Our company manages all of its projects using Advanced Product Quality Planning (APQP), and our workforce is equipped with well-defined roles and responsibilities to ensure that the highest quality standards are met.

In addition to our advanced manufacturing and testing capabilities, Best Cast will set up a customised, comprehensive project plan that ensures total customer transparency throughout all project stages, resulting in effective communication for a prosperous launch.

TOOL ROOM

Tool design and development is a crucial aspect of the die casting process at our manufacturing company. Our manufacturing company prioritises these critical steps to ensure the production of the highest quality products for our valued customers. Our die casting process is dependent on the accuracy and dependability of our tools, specifically our dies and moulds. The process involves identifying the need for a new tool or an improvement in an existing tool, designing and prototyping the tool, testing and evaluating its performance, and finally, manufacturing the tool at scale.

Our expert team of designers, engineers, and project managers are dedicated to ensuring the highest quality of our tools. We meticulously simulate the performance of each tool under various conditions to identify any potential issues such as interference, stress concentration, and wear. Rest assured that our team will be involved at every step of the manufacturing process to ensure the best possible outcome for our customers. Our company is committed to providing top-quality products that are designed for optimal performance and longevity. We take pride in our ability to make necessary design refinements that not only improve product performance but also reduce costs.

At Best Cast, We specialise in designing the finest feeding systems that optimise workflow and minimise project delays. Our company recognises the importance of utilising advanced data analytics in order to guarantee the highest level of quality and consistency in our finished goods.

Alloy Making

Tool design and development is a crucial aspect of the die casting process at our manufacturing company. Our manufacturing company prioritises these critical steps to ensure the production of the highest quality products for our valued customers. Our die casting process is dependent on the accuracy and dependability of our tools, specifically our dies and moulds. The process involves identifying the need for a new tool or an improvement in an existing tool, designing and prototyping the tool, testing and evaluating its performance, and finally, manufacturing the tool at scale.

Our expert team of designers, engineers, and project managers are dedicated to ensuring the highest quality of our tools. We meticulously simulate the performance of each tool under various conditions to identify any potential issues such as interference, stress concentration, and wear. Rest assured that our team will be involved at every step of the manufacturing process to ensure the best possible outcome for our customers. Our company is committed to providing top-quality products that are designed for optimal performance and longevity. We take pride in our ability to make necessary design refinements that not only improve product performance but also reduce costs.

At Best Cast, We specialise in designing the finest feeding systems that optimise workflow and minimise project delays. Our company recognises the importance of utilising advanced data analytics in order to guarantee the highest level of quality and consistency in our finished goods.

SHELL CORE MAKING

The shell core manufacturing process involves creating a shell of sand and resin around a heated metal pattern. After the molten metal is poured into the mold, a hollow cavity with the desired shape is formed in the casting.

Best Cast specializes in Shell Core Making and produces complex cores for small and large castings across a wide range of applications and industries. We have in-house expertise in various shell core manufacturing processes as well as shell core boxes.

Gravity Die Casting

With over five decades of expertise in Gravity Die Casting, also known as Permanent Mould Casting, Best Cast Foundry can manufacture aluminium castings up to 50 kilogrammes in weight with the use of metal, shell, or sand cores in order to produce intricate internal features. The degree of dimensional accuracy and shape precision that our Castings deliver is steadfastly high. Gravity die castings deliver a cost-effective solution for high volume requirements. Our foundry leverages extensive knowledge and deep industry experience to provide highly competitive solutions. With comprehensive capabilities across the entire spectrum of Die Casting processes, Best Cast meticulously controls quality to ensure that the final casting meets all reliability, durability, and safety standards.

Heat Treatment

Best Cast has advanced machinery for heat treatment of aluminum castings, specifically designed for Solution & Precipitation Treatment (T6 condition). Our foundry produces aluminium castings that are primarily used in the ‘as cast’ condition. However, we also cater to specific applications that demand superior mechanical properties or distinct properties from the as cast material. The heat treatment of aluminium castings is carried out to change the properties of the as cast alloys by subjecting the casting to a thermal cycle or series of thermal cycles.

Our furnaces are meticulously engineered to facilitate uniform heat transfer across all areas of the castings. With drop quench furnaces enabling rapid quenching and uniform convective heating, our carefully designed fan and duct configurations guarantee precise temperature uniformity throughout the load chamber and parts.

At Best Cast, our consistent commitment to quality is reflected in the strict adherence to comprehensive quality control measures throughout our heat treating processes.

PRECISION CNC MACHINING

Best Cast offers a comprehensive range of CNC machining capabilities, catering to both rapid prototyping, low-volume production, and high-volume production of end-use components.

In addition to our state-of-the-art equipment capabilities, Best Cast operates on a well-defined manufacturing strategy, leveraging advanced machinery, cutting-edge tools, and sophisticated software. This enables us to produce complex parts with unparalleled accuracy and efficiency, meeting the most demanding requirements.

We take great pride in our team of highly skilled machinists who possess expertise in operating CNC machines. We utilize the latest techniques and adhere to stringent quality control measures, ensuring exceptional precision in every part we manufacture.

To support our machine shop, we have a dedicated temperature-controlled inspection department equipped with Coordinate Measuring Machines (CMM), as well as a wide range of conventional measuring equipment.

SECONDARY FINISHING PROCESSES

Best Cast’s expertise in finishing processes encompasses a range of operations performed to improve the surface finish, dimensional accuracy, appearance, performance and durability of castings. The specific finishing processes used for each product depend on the desired properties of the final component and the requirements of the application.

L

TRIMMING

Trimming is the process of removing excess material, such as flash or gate marks, from the casting using a cutting tool or grinder. This process is necessary to achieve the desired shape and dimensions of the casting.
L

DEBURRING

Deburring is the process of removing any burrs or sharp edges from the casting using a grinding or polishing tool. This process can help to improve the casting’s appearance and reduce the risk of injury during handling.
L

SANDING & POLISHING

Sanding and Polishing are processes used to smooth the surface of the casting and to create a high-quality, mirror-like finish. These processes can be performed manually or using automated equipment, such as buffing machines.
L

SHOT BLASTING

Shot Blasting is a surface finishing process that is commonly used on die cast products. It involves the use of high-velocity steel abrasive particles or shot to blast the surface of the die cast product to remove any remaining impurities, such as oxide scale, burrs, or other surface contaminants.
L

IMPREGNATION

Impregnation is a process that seals porosity, providing components that are waterproof. A really workable solution that will both increase your yields and cut down on your scrap. Also an excellent choice to make after the machining process, when the skin of the casting must be removed in order to produce a leak-free component.
L

PAINTING & POWDER COATING

Painting refers to the procedure of imparting a protective or decorative coating to the surface of a casting. Lacquer, moist spray, and enamelling are the most prevalent types of painted coatings. Powder coating is one of the most commonly used coatings. As a consequence of being cured at higher temperatures, the finish is significantly more durable. Generally, resistance to scratches and fractures. Both Painting and Powder Coating is available in numerous tints, sheen levels, and surface textures. Due to the fact that it is cured at higher temperatures, the die casting procedure must be exceptionally well-controlled.
L

HARD ANODISING

Hard anodising is a type of anodising process used to create a thicker and more durable oxide layer on the surface of a die cast product. Anodising is an electrochemical process that converts the surface of a metal object into an oxide layer, which provides improved corrosion resistance, increased surface hardness, and other desirable properties.
L

Alochroming

Aluminium may be strengthened and polished by the use of a chemical process called Alochroming, which is sometimes known as Chromating or Alodining. Chromating applies a chemical solution to the casting so that it may be preserved for longer. The surface of the component is oxidised chemically by using this method. The Alochroming process makes the material more corrosion resistant.
L

Electroless Nickel

Instead of employing electrolysis, nickel is submerged in a specific solution during our electroless nickel plating process. Our solution guarantees a consistent plating thickness. Options with low to high phosphorus levels are offered. Bath’s phosphorus content. As the concentration of phosphate falls, nickel’s density increases. Although the low-concentration finish is delicate, it has excellent wear characteristics, and high-concentration finish enhances ductility.
L

Silver Plating

Excellent electrical, thermal connectivity, and corrosion resistance are provided by aluminium silver plating for vital applications in power transmission and distribution applications. Inexpensive yet prone to tarnishing when exposed to the environment. In addition to having good lubricity and anti-galling qualities in high temperature applications, silver is very ductile, malleable, and solderable.

INSPECTION & ASSESSMENT

The majority of our inspection techniques are based on Non-Destructive Testing (NDT) Methods.

L

Visual Inspection

Our inspection process includes a thorough visual examination, which can be conducted manually or with the assistance of specialised equipment like magnifying glasses and boroscopes. This method allows us to identify surface defects such as cracks, porosity, and surface finish.
L

Dimensional Inspection

This inspection method involves measuring the dimensions of the die cast part using specialised equipment such as Coordinate Measuring Machines (CMMs), Profile Projectors and Speciality Gauges. This inspection method ensures that the parts meet the required dimensional tolerances. A CMM programme that has already been created and authorised is used to inspect components. This gets rid of human error by automatically checking each component in the same way and comparing the results to the design specifications that were already entered.
L

Chemical Analysis

This inspection method involves the use of chemical analysis techniques such as spectroscopy and chromatography to analyse the composition of the die cast part. This inspection ensures that the part meets the required chemical composition standards.
L

Mechanical Testing (UTM)

This inspection method involves testing the mechanical properties of the die cast part, such as Tensile strength, Elongation, Yield. This inspection ensures that the parts meet the required mechanical properties standard. that the final product meets all reliability, durability, safety and cost parameters.
L

Penetrant Testing

Our advanced technology can accurately identify even the smallest microscopic fissures, cavities, and surface discontinuities on a wide range of materials.Our castings undergo immersion in penetrant, which is then drawn into any discontinuity through capillary action. Our casting undergoes a thorough inspection process using ultraviolet light to detect any surface indications and ensure its integrity.
L

Helium Leak Testing

Helium leak detection technique is far more precise and dependable when compared to conventional atmospheric air leak testing. Our Helium Leak Testing service is a non-destructive quality control inspection that ensures our manufactured components are leak-proof and free from any fluid leakage. We can also perform dry and hydro leak testing in addition to helium leak testing.
L

Ultrasonic Inspection

The ultrasonic inspection method utilises high-frequency sound waves to thoroughly examine the internal structure of your die cast parts. Our inspection process is designed to detect internal defects, including voids, cracks, and inclusions that are not visible through standard visual inspection methods.
L

Radiographic Inspection

One of the best ways to find flaws like porosity is radiographic examination. X-rays are directed towards the direction of the casting as part of the radiography procedure. While some X-rays are absorbed by the casting, others travel through and are detected by digital detectors to produce pictures. If the casting satisfies the acceptance requirements, it may be determined by looking at the generated photographs.
L

Ultrasonic Cleaning and Millipore Testing

Through the application of an ultrasonic solution on inert, non-absorbent components, pollutants including dust, fibres, oils, metal chips/fines, and soot may be removed from intricately shaped areas like cavities, blind holes, tubes, fissures, and crevices for further Millipore testing. After the casting has been cleaned, the component is put through Millipore testing to establish its maximum impurity value. It represents an index of cleanliness.

INFRASTRUCTURE GALLERY

BEST CAST IT LIMITED

Cast your Imagination

Our commitment to exceptional service makes us
the most trusted partner in the Die Casting industry.

Copyright © 2024 | BestCast | bestcastgroup.com | All Rights Reserved