What metal casting process is right for my part?

It depends on your geometry, material, and production volume. Pressure die casting fits high-volume parts. Gravity die casting suits medium volumes. Investment casting works for complex details. Sand casting is better for large or low-volume components.

What production volumes are suitable for different casting processes?

Pressure die casting is usually better for higher volumes, while investment casting and sand casting provide more flexibility for prototypes and low-volume production.

Do you offer prototypes and low-volume metal casting?

Yes. Prototype casting helps validate fit, function, and material selection before production tooling investment.

What materials are available for metal casting services?

Mastars supports aluminum, stainless steel, carbon steel, iron, zinc, and copper alloys. Material selection depends on strength, corrosion resistance, weight, environment, and casting process.

Can you optimize my design before casting?

Yes. We review geometry, wall thickness, draft angles, material choice, and casting risks through DFM analysis.

What accuracy can metal casting achieve?

Accuracy depends on the casting process and part design. Critical features can be machined and verified through inspection.

How do you control quality?

Quality control includes engineering review, process monitoring, dimensional inspection, and required documentation such as FAI reports.

Do you provide manufacturing beyond casting?

Yes. Mastars supports tooling, CNC machining, finishing, assembly, and inspection for complete metal component delivery.

Can you provide surface finishing and secondary machining for cast parts?

Yes. Available options include CNC machining, blasting, polishing, coating, anodizing, plating, and other finishing processes for functional and appearance requirements.

What files do you need for a metal casting quote?

Send 3D CAD files, drawings, material requirements, quantities, and finishing requirements. Rough information is enough to start.

Metal Casting – Mastars

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Services

Metal Casting

10^Days

T1 Sample Support

0.002^mm

Mold Precision

50^–60

Molds / Month

100^K

Production Scale

Metal Casting Capabilities

Pressure Die Casting

High-volume aluminum, zinc, and magnesium parts with fast cycles, consistent dimensions, and production support from thousands to 1M+ units.

Gravity Die Casting

Medium-volume aluminum and non-ferrous parts using reusable metal dies for better consistency than sand casting, with lower tooling investment than pressure die casting.

Sand Casting

Large, complex, or low-volume castings with flexible tooling, broad material options, and greater design freedom.

Lost Wax Casting (Investment Casting)

Complex metal components with fine details, near-net-shape capability, and reduced machining requirements for stainless steel, steel, aluminum, and high-performance alloys.

Which Metal Casting Process Is Right for Your Part?

The right casting process depends on part geometry, material, production volume, and required performance.

Process	Best For	Material Options	Key Advantage	Key Trade-off	Typical Applications	Engineering Review Before Production
Pressure Die Casting	High-volume parts	Aluminum, Zinc, Magnesium alloys	Fast cycles and repeatability	Higher tooling investment	Automotive, electronics, housings	Part geometry, wall thickness, draft angles, tooling design, filling behavior, and casting defect risks
Gravity Die Casting	Process and capacity require confirmationMedium-volume structural parts	Aluminum, Aluminum alloys, Brass, Copper alloys	Better mechanical properties and lower tooling cost	Slower cycle than HPDC	Machinery, structural parts	Material selection, mold design, feeding system, solidification behavior, and dimensional requirements
Investment Casting	Complex precision parts	Stainless steel, Carbon steel, Aluminum alloys, High-performance alloys	Excellent detail reproduction	Higher process cost	Medical, aerospace, precision parts	Part geometry, wax pattern design, shrinkage allowance, alloy compatibility, and critical dimensions
Sand Casting	Large or low-volume parts	Iron, Steel, Aluminum alloys, other ferrous and non-ferrous metals	Maximum design flexibility	More machining allowance	Large machinery, industrial equipment	Pattern design, casting allowance, material behavior, wall thickness, and finishing requirements

From Casting Prototypes to Production Parts

Validate casting designs before tooling investment, then move into repeat production with optimized processes and quality control.

Prototype Casting

Validate casting feasibility before production tooling investment.

T1 samples in as fast as 10 days
Fit, assembly & functional validation
Material behavior verification
Casting design improvement feedback

Explore Prototyping

Production Casting

Scale validated designs into repeatable metal production with controlled tooling, casting processes, and quality inspection.

1 to 100,000+ units supported
Production tooling for repeat builds
CNC machining & finishing integration
FAI, CMM & critical-dimension control

Explore Production

Custom Metal Casting Services for Complex Projects

Mastars supports complex metal casting projects where geometry, material selection, tooling strategy, and secondary processes require careful engineering decisions.

Our engineers evaluate geometry, material requirements, and casting feasibility to help move designs from prototype validation to production.

Get a Quote

Metal Casting Tolerances

Casting tolerances vary by process, alloy, part size, and geometry. Critical dimensions can be machined and verified after casting.

Casting Process	Typical Accuracy	Key Factors	Applications
Pressure Die Casting	±0.003–0.005 in/in (typical reference)	Mold accuracy, alloy behavior, filling, cooling control	Automotive, electronics, housings
Gravity Die Casting	Around ±0.1 mm reference, depending on size and geometry	Mold design, solidification, feeding system	Structural parts, machinery components
Investment Casting	Around ±0.005 in/in typical reference	Wax pattern, shell quality, shrinkage compensation	Medical, aerospace, precision parts
Sand Casting	Lower dimensional precision; machining often required	Pattern design, sand quality, shrinkage, machining allowance	Large equipment parts

Metal Casting Materials & Alloys

Aluminum

Zinc Alloys

Stainless Steel

Steel

Cast Iron

Copper Alloys

Aluminum

Aluminum casting is widely used for lightweight metal components requiring a strong balance of strength, corrosion resistance, and production efficiency. Aluminum alloys are suitable for pressure die casting, gravity die casting, and other casting processes across industrial applications.

Key Characteristics

Lightweight with high strength-to-weight ratio

Excellent corrosion resistance

Good thermal conductivity

Suitable for complex casting geometries

Compatible with machining and surface finishing

Common Grades: A380, ADC12, A356, A357

Typical Applications: Automotive Components, Electronic Housings, Industrial Equipment, Consumer Products, Lightweight Structural Parts

Available Finishes: Machining, Anodizing, Powder Coating, Painting, Shot Blasting

Zinc Alloys

Zinc alloys are suitable for small and complex cast components requiring excellent castability, dimensional stability, and surface quality.

Key Characteristics

Excellent castability

Good dimensional accuracy

Smooth surface finish

Suitable for high-volume production

Common Grades: Zamak 3, Zamak 5

Typical Applications: Hardware Components, Consumer Products, Automotive Parts, Electronic Components

Available Finishes: Plating, Painting, Powder Coating, Polishing

Stainless Steel

Stainless steel casting provides excellent corrosion resistance, durability, and mechanical performance for demanding industrial applications.

Key Characteristics

Excellent corrosion resistance

High strength and durability

Good temperature resistance

Suitable for harsh environments

Common Grades: 304, 316, 17-4PH

Typical Applications: Medical Components, Food Processing Equipment, Industrial Valves, Precision Components, Aerospace Parts

Available Finishes: Machining, Polishing, Passivation, Electropolishing, Shot Blasting

Steel

Steel casting is suitable for structural and heavy-duty components requiring high strength, toughness, and wear resistance.

Key Characteristics

High mechanical strength

Excellent impact resistance

Good wear performance

Suitable for large and complex components

Common Grades: Carbon Steel, Alloy Steel, 1020, 1045

Typical Applications: Industrial Machinery, Heavy Equipment Components, Structural Parts, Mechanical Components

Available Finishes: Machining, Painting, Shot Blasting, Protective Coatings

Cast Iron

Cast iron casting provides excellent wear resistance, vibration damping, and cost efficiency for large industrial components.

Key Characteristics

Excellent vibration absorption

Good wear resistance

Strong dimensional stability

Cost-effective for large parts

Common Grades: Gray Iron, Ductile Iron

Typical Applications: Machine Bases, Pump Housings, Industrial Equipment, Automotive Components

Available Finishes: Machining, Painting, Shot Blasting

Copper Alloys

Copper alloys offer excellent electrical conductivity, corrosion resistance, and wear performance for specialized casting applications.

Key Characteristics

Excellent conductivity

Good corrosion resistance

High wear resistance

Suitable for functional components

Common Grades: Brass, Bronze, Copper

Typical Applications: Valves, Fittings, Electrical Components, Bearings, Industrial Parts

Available Finishes: Machining, Polishing, Plating

Metal Casting Surface Finishing Options

Finishing depends on casting process, material, appearance, and functional requirements.

Finishing Option	Surface Characteristics / Performance	Suitable Materials	Typical Applications
As Cast Finish	Original casting surface with minimal secondary processing. A cost-effective option for functional components where appearance and tight surface requirements are not critical.	Aluminum, steel, iron, zinc alloys	Internal components, structural parts, industrial equipment
Machining	Improves dimensional accuracy and creates precise functional surfaces for critical features such as mounting areas, holes, and interfaces.	Aluminum, steel, stainless steel, iron, other cast alloys	Precision components, mechanical assemblies, mounting interfaces
Abrasive Blasting	Removes surface residues, improves surface consistency, and creates a uniform matte texture for appearance and further finishing preparation.	Aluminum, steel, stainless steel, iron alloys	Equipment housings, automotive parts, industrial components
Polishing	Enhances surface smoothness and appearance for visible components requiring a refined finish or reduced surface roughness.	Stainless steel, aluminum alloys, copper alloys	Decorative parts, precision components, consumer products
Powder Coating	Provides durable corrosion protection and decorative color options with excellent wear resistance for outdoor and industrial environments.	Aluminum, steel, iron alloys	Equipment housings, structural components, industrial products
Painting	Adds customized colors and protective coatings to improve appearance and environmental resistance.	Aluminum, steel, iron alloys	Automotive components, industrial equipment, custom metal parts
Plating	Adds corrosion resistance, wear resistance, conductivity, or functional surface properties through metallic coatings.	Steel, aluminum, zinc alloys, copper alloys	Hardware components, mechanical parts, electrical components
Anodizing	Enhances corrosion resistance, surface hardness, and appearance. Mainly used for aluminum castings requiring improved surface performance.	Aluminum alloys	Electronic housings, consumer products, industrial components
Heat Treatment	Improves mechanical properties such as strength, hardness, and fatigue resistance through controlled heating and cooling processes.	Aluminum alloys, steel, iron alloys	Structural components, automotive parts, load-bearing components

Metal Casting Equipment & Inspection Capabilities

Production Equipment (Demo)

Process Control Equipment (Demo)

Inspection Equipment (Demo)

Metal Casting Project Showcase

Why Choose Mastars for Metal Casting?

Certified Quality Systems

ISO 9001, ISO 13485, and IATF 16949 certified processes help ensure consistent quality across industrial, medical, and automotive projects.

100+ Engineering Professionals

Work directly with experienced engineers for DFM reviews, tolerance recommendations, and manufacturing support—without unnecessary back-and-forth.

5+ Production Bases

Flexible manufacturing capacity supports both urgent prototypes and scalable production without single-site bottlenecks.

No Minimum Order Quantity

Order one part or thousands—without unnecessary volume commitments or tooling investments.

DFM Review on Every Order

Identify manufacturability risks early to reduce redesign cycles, save costs, and improve part performance before production begins.

800+ Customers Served

Trusted by global engineering teams across industrial equipment, medical devices, robotics, automotive, and consumer products.

Certifications

ISO9001:2015 Certificate

IATF16949:2016 Certificate

ISO13485:2016 Certificate

Medical A-Class Supplier

Partners

How Metal Casting Works

Upload Your Design

Share your CAD files, drawings, quantity, material, and any critical requirements.

Get an Engineer-Reviewed Quote

Receive pricing, lead time, and manufacturability feedback based on your part requirements.

Production Begins

Once you approve your quote, manufacturing starts — from prototype tooling to full-scale runs.

Parts Shipped

Finished parts are inspected, packaged, and shipped with the required quality documentation.

Get a Quote

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