Casting is one of the oldest and most widely used metal forming processes, dating back to ancient civilizations and continuing to play a vital role in the development of modern industries. In this process, molten material (usually metals) is poured into molds, where it solidifies to form the desired shape. Casting is the foundation for manufacturing a wide range of industrial components, heavy equipment, metal structures, and precision tools.
Casting has a history of thousands of years. The earliest historical evidence dates back to around 3000 BC in ancient Egypt, China, and India. In Iran, numerous archaeological artifacts have been discovered that highlight the advanced skills of ancient craftsmen in metal casting.
Casting is a manufacturing process in which molten metal or alloy is poured into a mold that defines the final shape of the part. After cooling and solidification, the metal takes the desired solid form. Molds may be made of sand, metal, graphite, or ceramic, depending on the requirements of accuracy, dimensional tolerance, and material selection.
Sand Casting
One of the oldest and most common casting methods.
Uses sand molds for shaping molten metal.
Advantages: low cost, suitable for large parts.
Investment Casting (Lost-Wax Casting)
Ideal for parts requiring high precision and intricate details.
Uses wax patterns coated with ceramic to form the mold.
Die Casting
Molten metal is injected into metal molds under high pressure.
Widely used for mass production of thin-walled, precise components.
Centrifugal Casting
Utilizes centrifugal force to fill molds.
Commonly used for pipes and cylindrical parts.
Continuous Casting
Mainly used for producing billets, blooms, and slabs.
Essential in the steel industry for high-volume production.
Model Design – Creating a pattern of the part (wood, metal, plastic).
Mold Making – Building the mold based on the pattern.
Melting – Heating the chosen metal/alloy in furnaces.
Pouring – Introducing molten metal into the mold.
Cooling & Solidification – Controlled cooling for final shape formation.
Shakeout & Finishing – Removing mold material, cleaning, machining, heat treatment, and inspection.
Ability to produce complex geometries
Production of parts in various sizes (from grams to tens of tons)
Suitable for mass production
Cost efficiency in material usage
Flexibility in alloy selection
Requires specialized equipment for quality control
Possibility of porosity, shrinkage, and defects
Dimensional contraction during cooling
Skilled labor required for critical stages
Automotive Industry
Engine blocks, gear housings, suspension parts, and transmission components.
Aerospace Industry
Lightweight alloys (aluminum, titanium) in precision molds for high-performance parts.
Oil & Gas Industry
Valves, fittings, pump housings, and corrosion-resistant drilling equipment.
Power Generation
Turbine components, generator housings, and heavy-duty parts.
Railway and Heavy Transportation
Wheels, axles, couplings, and heavy machine components.
Computer simulations for mold design and defect prediction
3D printing for rapid prototyping and mold/model fabrication
Non-destructive testing (NDT) for quality assurance
Energy-efficient melting and furnace technologies
Casting remains one of the most critical manufacturing processes in the modern industrial world. With technological advancements, the process has become more efficient, accurate, and cost-effective. Proper alloy selection, mold design, and process control are key to achieving successful outcomes.
Peyman Nou Industrial Group, leveraging its technical expertise and experience, provides high-quality casting services for complex and heavy industrial applications, tailored to the needs of various industries.
