Prototyping & Manufacturing / Iron Casting

Iron Casting

Iron Casting, Gray Iron Casting, Ductile Iron Casting

Aluminium · Carbon steel · Stainless
Certified welders
5 assembly lines
ISO 9001:2015 Certified

Cast Iron Materials

We provide reliable green sand casting, resin sand casting, and high-precision shell mold casting solutions. Because we are an ISO9001-certified manufacturer, our team produces all components according to strict international engineering standards. As a result, global industries trust X-PRO LLC to deliver exceptional ductile iron castings, durable shell mold castings, and custom gray iron components.

Gray Iron

Gray iron is a cost-effective alloy composed of carbon, silicon, and iron. Because it features high vibration damping and lower tensile strength, it tends to fracture suddenly under extreme stress rather than bending. Common Applications: Engine blocks, pump housings, valve bodies, electrical boxes, and decorative castings.

Pearlitic Malleable Iron

Through a specialized annealing heat treatment, we transform brittle as-cast structures into high-strength components. This process allows carbon to form into small spherical graphite aggregates. Consequently, the metal can flex easily without breaking. Common Applications: Hand tools, electrical fittings, pipe brackets, mining hardware, and farm equipment.

Ductile Iron

Also known as nodular cast iron, ductile iron delivers an exceptional yield strength that surpasses malleable iron. As a result, components manufactured with this material can bear significantly heavier operational loads. Common Applications: High-stress industrial gears, structural machinery mounts, and heavy-duty automotive parts.

Sand Casting Production Floor:

Our Advantage:

Consistent Quality
English Speaking Engineering Team
Full Solution: Machining, Coating, Assembly

The Shell Molding Process

Pre-Coating

Industrial sand is thoroughly pre-coated with a synthetic bonding resin.

Pattern Application

A heated metal tool pattern is evenly coated with the resin-sand mixture.

Thermal Curing

Heat cures and hardens the material into a rigid shell measuring 0.5″ to 1″ thick.

Shell Stripping

The cured shell halves are stripped from the pattern and glued together to form a central cavity.

Metal Pouring

Molten metal is poured directly into the assembled shell mold on our conveyor line.

Cooling & Finishing

After cooling, the sand shell is stripped away, recycled, and prepped for final surface machining.

Shell Mold Casting:

Material Choices:

Pearlitic malleable iron ASTM A220: 40010 (DIN GTS-45),50005…
Ductile cast iron ASTM A536: 60-40-18 (DIN GGG40), 65-45-12, 70-50-05…
Grey cast iron ASTM A48: Class No.60 (DIN GG40) to No.400 …

Casting Manufacturing Methods

Green Sand Casting

Green sand molding remains one of the most versatile and economical manufacturing options available.
Key Benefits: Low pattern tooling costs, compatibility with almost all ferrous and non-ferrous metals, and no physical size or weight limits.
Best Used For: Rapid prototyping, small production runs, and medium-sized bench-molded components.

Resin Sand Casting

This method utilizes advanced synthetic binders that cure chemically or thermally. By reinforcing the structural sand mold, we can successfully cast highly complex geometric shapes with excellent dimensional tolerances.

Shell Mold Casting

Shell molding significantly reduces production cycle times while offering superior surface finishes. Our facilities apply this process to cast irons, aluminum, and copper alloys alike.
Common Parts: Connecting rods, gear housings, lever arms, and precision brackets.

Continuous Casting Line

Scope

How Can X-Pro Help With My Project?

X-PRO helps clients with one-time and ongoing project needs. Submit your project description and work with a pre-qualified 3D artist, CAD designer, drafter, modeller, animator or engineer specialised for your needs.

OUR SPECIALTIES

3D modeling
Prototype design
3D design
3D printing design
CAD drafting
Mechanical design
3D animation
Manufacturing
Engineering & 3D renderings
Structural design
3D industrial design
Reverse Engineering

OUR DESIGNERS AND DRAFTING CONTRACTORS WORK WITH

AutoCAD
3ds Max
SolidWorks
CATIA
Autodesk Inventor
Maya
and many more

Three Steps

The Project Flow

Tell us about your project

Describe your project, estimate the number of hours needed, the duration, and software requirements.

Pre-qualified expert freelancer

One of our engineers will contact you to discuss your project and gather more details.

Deposit & work

Agreement will need to be signed and payment deposit made in order to begin a project.

FAQ for your new project

Why X-PRO LLC?

We connect you with the best designers in the business, and we offer the most comprehensive set of services for inventors you’ll find anywhere. We take the guesswork out of online design services, and let you focus on what’s important.

How do private projects work?

Simple. Just send us a project brief and we will provide you with a design quote from a pre-qualified designer for your project.

Who can see my project?

Private projects are entirely confidential. Only you and the designer that you will be working with will see your project description, file attachments and submitted work.

Do I own the designs & IP?

Yes. Our legally binding terms of service assign the ownership of intellectual property (IP) from the designer to the service buyer for any paid designs.

Do you offer manufacturing services?

Yes we do! We offer a range of manufacturing services, including 3D printing, rapid manufacturing and conventional injection molding.

How is a design project different from hourly services?

Design projects are limited-term projects with a concrete budget, based on an upfront quote from the CAD designer. Hourly services are for ongoing work that generally have an open work scope.

Will designers sign a NDA?

We’ve got this covered. Our legally binding terms of service covers freelancer non-disclosure. Freelancers on X-Pro have agreed to and are bound by the terms of non-disclosure that are outlined in our terms of service.