FOUNDRY PRODUCTION

FOUNDRY PRODUCTION

Steel, cast iron and non-ferrous metal castings according to customer documentation

PRITZ DEVELOPMENT supplies custom metal castings — parts and semi-finished products according to customer drawings, 3D models and technical documentation, with subsequent machining if required.

We manufacture custom castings from cast steel, cast iron and non-ferrous metals in sand moulds (using moulding sand) and permanent moulds.

FOUNDRY PRODUCTION
FOUNDRY PRODUCTION
TECHNICAL CAPABILITIES

Types of castings


Manufacture of steel castings for machine assemblies, housings, equipment parts and other key components.
The cast steel grade can be selected according to the drawing requirements, technical specifications and operating conditions of the part.
01

Steel castings

Material: carbon cast steel, low-alloy cast steel.
Casting weight: from 10 to 1500 kg. MORE 02

Cast iron castings

Material: grey cast iron
Casting weight: from 0.5 to 1500 kg. MORE 03

Casting from aluminum

Material: aluminium alloys
Casting weight: from 0.4 to 120 kg. MORE 04

Non-ferrous metal castings

Material: copper-bronze alloys
Casting weight: from 0.4 to 120 kg. MORE

From a cast blank to a finished part

A metal casting can be supplied as a semi-finished product or, after machining, as a finished part that conforms to the drawing.

This makes it possible to obtain a finished part that conforms to the customer’s drawing without having to coordinate cooperation between the foundry and the machining facility yourself.

Possible sequence of production stages:

1. Analysis of the drawing and technical documentation.

2. Selection of the material and manufacturing process.

3. Manufacture of the cast blank.

4. Cleaning and preparation of the casting.

5. Heat treatment — if necessary and in accordance with the requirements for the part.

6. Machining.

7. Dimensional inspection and quality control.

8. Kitting and preparation of products for shipment.

Production based on customer documentation

Work begins with an analysis of the technical documentation.

For a preliminary assessment, it is sufficient to provide:

  • a part drawing;
  • a 3D model;
  • the material grade;
  • the required number of pieces;
  • mechanical property requirements;
  • machining requirements;
  • inspection and quality requirements.

If the documentation includes requirements for a specific manufacturing process, these are taken into account when preparing the quotation.

For products manufactured in series, the manufacturing process and cast blank parameters can be agreed before production begins.

We manufacture tooling for foundry production (cast steel moulding boxes, welded moulding boxes, permanent moulds) and pattern sets made from wood and aluminium alloys.

The metal casting is inspected in accordance with the documentation requirements. We agree on the scope of testing for each project.

Quality control methods used: rapid chemical composition analysis, chemical analysis, mechanical testing, microstructural examination, photocolorimetry, leak testing, ultrasonic testing, dye penetrant testing, dimensional accuracy inspection, pouring temperature monitoring, testing of moulding and core material properties, spectral analysis, magnetic particle testing.

Additional capabilities: heat treatment, machining, design and manufacture of pattern equipment on a TWISTERSX five-axis machining centre

What applications is this production suitable for

Casting and machining capabilities can be used to manufacture:

  • housings and housing parts;
  • covers and bases;
  • machine and mechanism parts;
  • gear and drive components;
  • supports and brackets;
  • working components of equipment;
  • large machine parts;
  • spare parts;
  • other cast parts according to customer drawings.

The main area of activity is industrial and machinery manufacturing, including one-off, small-batch and series production of parts, depending on the nature of the project.

Machining of cast parts

After the casting has been produced, machining can be carried out to obtain a finished part that conforms to the drawing.

Machining is performed using lathes, milling machines, boring machines and other metalworking machine tools.

For machining large parts, the production facility has modern equipment capable of processing components of considerable dimensions and weight. In particular, the facility uses a DOOSAN DBC160 five-axis horizontal boring machine designed to machine parts weighing up to 2 tonnes and measuring up to 4 metres in length.

Depending on the project, a full production cycle can be organized:

Casting → heat treatment → machining → inspection → finished part.

ADVANTAGES OF PRODUCTION AT PRITZ DEVELOPMENT

One manufacturing partner for the entire product

Full production cycle

Working from customer documentation
Production of parts and products according to drawings, 3D models and specifications.

Production repeatability
Consistent manufacture of identical components and products.

Production of trial units
Verification of the design and manufacturing process before launching series production.

Assembly of finished products
The option to receive a finished assembly or product instead of individual parts.

Quality control
Product inspection during manufacturing and before delivery.

ISO 9001
An implemented quality management system confirmed by certification.

A company headquartered in Poland
PRITZ DEVELOPMENT is headquartered in Katowice and focuses on B2B projects in Poland and EU countries.

HOW WE FULFIL AN ORDER

From a drawing to a finished part, assembly or product

01 — Documentation
We receive drawings, 3D models and specifications.

02 — Technical analysis
We check the design and manufacturability.

03 — Quotation
We determine the production process sequence and cost.

04 — Trial unit / pre-production run
We manufacture a trial unit or a small batch.

05 — Approval
We agree on the design and quality.

06 — Series production
We launch regular production.

07 — Assembly and inspection
We assemble the units and inspect the finished products.

08 — Packaging and delivery
We prepare the products for shipment.

PRITZ DEVELOPMENT · KATOWICE

FOUNDRY PRODUCTION

If you have a drawing of a cast part, a 3D model or a specification, send the documentation — we will forward it for technical assessment and prepare a production quotation.

CASTING
PROCESS SELECTION AND ENQUIRY PREPARATION
Pressure die casting and project requirements Pressure die castings are produced by forcing molten alloy into a metal mould under pressure. The die casting process is selected according to the material, part geometry and planned production run size. High-pressure die casting is used, among other applications, for the series production of thin-walled parts. We confirm the feasibility of such projects and their parameters after a technical assessment. The weight ranges specified above apply to castings produced in sand moulds and permanent moulds.
Cold-chamber and hot-chamber die casting Cold-chamber die casting involves transferring molten metal from a separate furnace to the injection chamber. In hot-chamber die casting, the injection system remains in contact with the molten metal in the furnace. The choice of method depends primarily on the alloy properties and process requirements.
Geometry, weight and dimensional requirements When a project includes thin-walled parts, wall thickness, mould filling and cooling conditions are important. Complex geometry and casting weight influence the selection of the manufacturing process and tooling. Dimensional accuracy, dimensional tolerances and surface quality should be specified in the documentation.
Mould design and introducing a part into production Mould design involves determining the mould parting arrangement, metal feeding, venting, cooling and casting ejection. Technical documentation and technical drawings provide the basis for these decisions. For a new project, the scope of design work, tooling manufacture and assessment of the first parts are agreed. Introducing a part into series production requires approval of the agreed parameters and acceptance criteria.
Porosity and leak testing Porosity requirements are specified with reference to the function of the part and the areas subject to further machining. If leak testing is required, the test conditions and acceptance criteria are established before work begins. The scope of quality control is tailored to the requirements of the particular part.
Surface finishing and further processing Machining makes it possible to produce the holes, mounting surfaces and fits specified in the documentation. Vibratory abrasive finishing is one method of removing burrs and smoothing edges; its use must be suited to the material, shape and expected finish. We confirm the scope of such operations for each specific project.
Quotation for pressure die castings Cost assessment requires information about the alloy, part weight and geometry, production run size and required processing. The unit cost of a casting also depends on the tooling and the planned number of repeat orders. The cost calculation for a metal casting accounts separately for tooling preparation and the manufacture of individual parts. We prepare the quotation after confirming the manufacturing process and project feasibility.
Country of production requirements If Polish-made castings are required, the country of manufacture should be specified in the enquiry. We verify the production location and the scope of documentation confirming it when preparing the quotation.