Die Casting Service

From initial concept to final delivery, our comprehensive services cover every step of the product development process.

Die Casting

At XM Group, we offer a comprehensive range of casting solutions. Our low-pressure die casting(LPDC) and gravity die casting(GDC) processes allow us to deliver complex metal prototypes and Low-volume production parts with unparalleled speed, intricate detail, and superior quality. 3D printing technology for creating sand molds is a game-changer for the sand casting industry, enabling unprecedented design freedom and speed.

Our Capabilities

Design & Pattern Making: Our engineers collaborate with you to optimize your design for manufacturability. We then create precision patterns (often 3D printing and CNC Machining) which define the mold cavity.
Mold Creation: Sand, mixed with bonding agents, is packed around the pattern within a flask. We utilize various advanced sand systems chosen for optimal surface finish, dimensional accuracy, and complexity requirements for your part.
Mold Assembly: Cores (sand shapes creating internal features) are precisely placed, and mold are assembled securely.
Melting & Pouring: Metal is melted in controlled furnaces to precise temperature and chemistry specifications. The molten metal is carefully poured by our skilled technicians into the mold cavity, relying solely on gravity to fill it.
Cooling & Solidification: The filled mold is allowed to cool naturally, enabling controlled solidification critical for part integrity.
Shakeout & Cleaning: Once solidified, the sand mold is broken away, revealing the raw casting. Gates, runners, and risers are removed.
Finishing & Inspection: Parts undergo cleaning (shot blasting, grinding) and meticulous inspection (dimensional checks, visual, NDT as required) to ensure they meet desired quality standards.

Technology: Binder jetting or resin-printed sand molds.
Benefits:
- Produce functional prototypes & production parts in days (vs. weeks).
- Optimize designs with iterative mold adjustments at minimal cost.
- Achieve fine details & thin walls impossible with traditional methods.
Applications: Engine blocks, pump housings, large industrial parts.

Our 3D-printed sand casting service supports a wide range of ferrous and non-ferrous metals, including but not limited to:

Aluminum Alloys
Steel Alloys
Iron
Bronze

This versatile process is ideal for a multitude of applications across various industries that demand high-performance, complex metal components, such as:

Aerospace: Intricate engine components, housings, and brackets.
Automotive: Prototyping of engine blocks, cylinder heads, and suspension parts.
Industrial Machinery: Complex pump housings, valves, and impellers.
Robotics: Customized structural components and end-effectors.
Energy: Turbine blades and other power generation components.

Our Material

Overview: A lightweight, corrosion-resistant metal with excellent thermal conductivity. It’s widely used in industries like aerospace, automotive, and electronics.

Key Properties: Lightweight, strong, corrosion-resistant, easy to machine.

Applications: Aerospace components, automotive parts, and electronics housings. Aluminum is commonly used for CNC machining, and sheet metal fabrication due to its ease of machining and thermal properties.

Overview: Known for its strength, durability, and excellent corrosion resistance, stainless steel is versatile across many industries.

Applications: Industrial equipment, medical devices, and structural components. Steel is ideal for CNC machining and sheet metal fabrication, particularly in environments requiring chemical resistance.

Brass

Overview: A copper-zinc alloy with excellent machinability and corrosion resistance, often used in precision parts.

Applications: Electrical connectors, plumbing components, and decorative parts. Brass is commonly machined and used in Low-volume production due to its ease of fabrication and good electrical conductivity.

Titanium

Overview: A strong, lightweight, and corrosion-resistant metal used in high-performance applications.

Applications: Aerospace parts, medical implants, and automotive components. Titanium is often used for CNC machining and 3D printing, especially in industries where strength and low weight are critical.

Key Advantages of Die Casting

Complex Geometries

Create parts with intricate internal passages, undercuts, and unique shapes difficult or impossible with 3D printing mold and sand casting.

Unparalleled Design Freedom

Easily creating complex structures and geometries and modify patterns and molds during the design process

Lower Tooling Costs

Sand molds (created from patterns) offer substantially lower initial tooling costs compared to permanent metal dies, accelerating prototype iterations and reducing risk.

Ideal for Small-to-medium Volumes

Perfect for functional prototypes, bridge tooling, pilot runs, and small-batch production where high-pressure die casting tooling is prohibitively expensive.

Why Us

At XM Group, we don’t just manufacture parts—we accelerate innovation. Our capabilities in CNC machining, 3D printing, sand casting and more allow us to use the best process for every single part of your project. Here’s why industry leaders trust us as their End-to-end prototyping and precision manufacturing partner.

End-to-end Capabilities

Simplify your supply chain. We combine sand casting, multi-axis CNC machining, industrial 3D printing under one roof. No juggling vendors. No compatibility gaps.

Fast Turnaround

Get functional prototypes and pre-production samples fast. Our integrated processes slash lead times while maintaining rigorous quality standards.

Flexible On-demand Production

Whether you need 1 prototype or 500 bridge-production units, our flexible capacity grows with your project—without sacrificing speed or precision.

Cost-effective

By eliminating the need for physical patterns and tooling, we significantly reduce upfront costs, making it economically viable to produce single prototypes or small batches of parts.

Ready for Manufacturing? Get a Free Quote & Expert Advice.

Have a CAD file or project specs? Our manufacturing engineers are ready to review your requirements and provide a fast, competitive quote for CNC machining, sand casting, 3D printing, binder jetting , or gear manufacturing.

Frequently Asked Questions.

What file formats do you accept for quoting and manufacturing?

We support all major CAD formats:
STEP, IGES, STL, SLDPRT, X_T, PARASOLID (and more).
Our engineers will review your design for manufacturability (DFM) and provide optimization suggestions before production begins.

What materials do you work with?

We offer a wide range of materials for various manufacturing processes, including:

Metals (Aluminum, Steel, Titanium, etc.)
Plastics (ABS, Nylon, Polycarbonate, etc.)
Composites and specialized materials depending on the application. We also provide material consultation to help you select the most suitable materials for your project.

Can you handle complex geometries or tight-tolerance parts?

Absolutely. Our 5-axis CNC machining centers (±0.01mm) and industrial 3D printers excel at:

Intricate designs, thin walls, and internal features
Tolerances down to ±0.025mm for critical dimensions
Challenging materials (e.g., Inconel, PEEK, tool steels)

Can I request a custom finish or post-processing for my parts?

Absolutely! We offer a wide range of surface finishes and post-processing options to enhance both the appearance and functionality of your parts. Whether you need polishing, anodizing, painting, or another specific finish, we can accommodate your requirements.

What is the lead time for your services?

Lead times vary depending on the service and project complexity. Rapid prototyping can typically be completed within a few days, while more complex manufacturing projects such as Low-volume production or tooling may take longer. Once we receive your project specifications, we’ll provide a detailed timeline.