High-volume metal forming capabilities delivering complex geometries, superior mechanical properties, and tight tolerances for aerospace, automotive, and industrial applications.
MetalCore's casting and forging division combines advanced metallurgy with automated production lines to deliver components that exceed industry standards. From low-volume prototyping to high-volume production runs, we optimize grain structure, minimize porosity, and ensure consistent part quality.
ISO 8062 Class 6-8 standard, custom ±0.02mm achievable
Up to 500,000 parts annually per tooling set
Melt-by-melt certification & heat treatment records
Radiography, ultrasonic, magnetic particle & dye penetrant
Select the optimal metal forming process for your material requirements, production volume, and performance specifications.
High-pressure injection into precision steel molds for complex, thin-walled components with excellent surface finish and dimensional stability.
Lost-wax process for highly intricate geometries, superior surface finish, and exceptional metallurgical integrity in exotic alloys.
High-energy impact forming that aligns grain flow for maximum strength, fatigue resistance, and impact toughness in critical components.
Simple, high-volume shaping of bar, plate, and billet stock into rings, shafts, and structural blanks with minimal material waste.
Gravity-fed or low-pressure casting into reusable steel molds, offering better mechanical properties than sand casting at lower cost.
In-house Nadcap-accredited services including solution annealing, precipitation hardening, stress relieving, and surface treatments.
Our controlled manufacturing process ensures consistency, quality, and on-time delivery.
CAD review, mold flow analysis, and design for manufacturability optimization.
Precision mold/die fabrication with rapid soft-tool prototypes for validation.
Automated melting, pouring/forging, and in-process quality monitoring.
Heat treatment, CNC machining, surface finishing, and final inspection.
Protective packaging, full documentation, and global logistics coordination.
Detailed capabilities for engineering reference and design validation.
| Parameter | Capability |
|---|---|
| Press/Injection Force | 500 - 1,600 Tons |
| Part Weight Range | 15g - 45kg (0.03 - 99 lbs) |
| Dimensional Tolerance | ±0.02mm to ±0.15mm (Class 6-8) |
| Surface Finish | Ra 1.6 - 6.3 µm standard |
| Wall Thickness | 0.5mm - 12mm minimum |
| Annual Capacity | 500,000+ units per mold |
| Tooling Life | 1,000,000 - 10,000,000 shots |
A356.0, A380, 356, 360, 380, 383, 413, 443, 508, 6061
Zamak 2, 3, 5, 7; AZ91D, AZ92; High-temp alloys available
1045, 4140, 4340, 8620, 304, 316, 17-4PH, 410, 420, 440C
Inconel 718/625, Titanium Ti-6Al-4V, Hastelloy, Bronze, Copper
Technical insights and process guidance for engineers and procurement teams.
Forging is preferred when high tensile strength, fatigue resistance, and impact toughness are critical. The mechanical working process aligns the metal's grain flow with the part geometry. Casting is ideal for complex geometries, thin walls, hollow sections, or when cost-effective high-volume production of less structurally critical components is required.
Standard steel die tooling typically requires 6-10 weeks from design approval to first article. Rapid prototype molds can be produced in 3-4 weeks. Complex aerospace or high-temperature alloy tooling may require 12-16 weeks depending on specifications and testing requirements.
Yes. We provide comprehensive AS9102-compliant First Article Inspection reports for aerospace clients. All production batches include material certifications, heat treatment records, NDT reports, and dimensional inspection data. Nadcap accreditation covers our heat treatment and non-destructive testing processes.
Absolutely. We offer full turnkey services. After forming, parts can undergo CNC milling, turning, drilling, tapping, and grinding in our adjacent machining facility. This eliminates second sourcing, reduces handling, and ensures tighter coordinate tolerances between machined and formed surfaces.
Submit your drawings or specifications for a comprehensive DFM analysis and competitive quote within 24-48 hours.