Capabilities
Intercast combines engineering support, rapid prototyping, investment casting and value-added manufacturing capabilities to help customers move complex components from development into production.
Our team works around the requirements of the part, helping customers evaluate manufacturability, develop the casting process and coordinate the operations needed to deliver a production-ready component.
Successful investment casting starts before production begins. Intercast works with customers to review component requirements and identify opportunities to improve manufacturability through the investment casting process.
Early collaboration can help address geometry, material selection, casting features and manufacturing considerations before tooling and production.
For components currently produced through machining, fabrication or multi-piece assemblies, our team can also help evaluate opportunities for conversion to a near-net-shape investment casting.
Design for Manufacturability
Component & Drawing Review
Casting Design Considerations
Material Considerations
Part Consolidation Opportunities
Tooling & Process Planning
Rapid prototyping provides a path to produce investment cast components for development and evaluation before committing to conventional production tooling.
Intercast can support prototype casting programs using expendable patterns produced through additive manufacturing methods, helping customers evaluate component designs and casting feasibility earlier in the development process.
Early Design Evaluation
Casting Feasibility
Prototype Components
Reduced Initial Tooling Commitment
Support for Product Development
Investment casting provides engineers with the freedom to produce complex geometries that may be difficult or costly to manufacture using other processes.
The process can create near-net-shape components with intricate features, allowing opportunities to reduce machining, eliminate fabrication steps and consolidate multiple components into a single casting.
Intercast applies its investment casting experience to develop production processes around the geometry, material, performance and quality requirements of each component.
Complex Geometries
Near-Net-Shape Components
Part Consolidation
Reduced Machining Opportunities
Design Flexibility
Repeatable Production
Material selection is a critical part of component performance. Intercast works with a range of ferrous and non-ferrous alloys to support different mechanical, corrosion, wear and temperature requirements.
Our team works with customers to understand the specified material and manufacturing requirements for each application.
Carbon & Alloy Steels
Stainless Steels
Nickel-Based Alloys
Copper-Based Alloys
Alloy availability and suitability depend on the specific component and project requirements. Contact Intercast to discuss the material requirements for your application.
Investment casting can reduce the amount of machining required, but many components still require finished dimensions, interfaces or other precision-machined features.
Intercast supports machining as part of the overall manufacturing solution, allowing casting and machining requirements to be coordinated around the finished component.
Machining capabilities are supported through a combination of in-house resources and external manufacturing partners based on the requirements of the project.
CNC Machining
Conventional Machining
Finished Casting Features
Casting-to-Machining Coordination
Heat treatment can be an essential part of achieving the mechanical and performance requirements specified for a cast component.
Intercast maintains in-house heat treatment capabilities and can also coordinate external processes when required by the material, specification or project.
Integrating heat treatment with the casting production process helps maintain control over the manufacturing sequence and component requirements.
In-House Heat Treatment
Vacuum Heat Treatment
Controlled Thermal Processing
Externally Coordinated Processes When Required
Some components require additional operations before they are ready for the customer's assembly or production line. Intercast can support and coordinate secondary processes as part of the overall manufacturing solution.
Depending on the project, these operations may be performed in-house or through external suppliers selected around the technical and quality requirements of the component.
Support for components requiring the combination of multiple castings or additional elements into a finished assembly.
Coordination of external surface treatment and finishing processes based on customer and application requirements.
Inspection and non-destructive testing capabilities are selected according to component, specification and customer requirements.
Other manufacturing and finishing operations can be coordinated as required by the project.
Inspection and testing requirements vary by component, industry and customer specification. Intercast incorporates the required verification activities into the manufacturing plan for each project.
Available capabilities include in-house inspection and non-destructive testing resources as well as externally coordinated testing when required.
Project Support
The right manufacturing solution may involve more than a casting process. Intercast works with customers to determine the combination of engineering, casting, machining, heat treatment, inspection and secondary operations required for the finished component.
Start Your Project
Send us your drawing and project requirements. Our team will review your application and help determine the right manufacturing approach.
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