Prototyping / Design

Your schedule is important to us! Bring your product to market quickly with parts that work for you. Tooling and casting samples in as little as 2-4 weeks.

We can provide an example of a prototype casting that can be used in your assembly to prove design.

We’ll take your sketches, fabrication, or CNC hog-out and our toolmakers and engineers will develop models of your part as a casting taking into consideration factors such as:

  • Casting method and material
  • Wall thickness
  • As-cast tolerances
  • Parting lines
  • Need for cores
  • Finish stock for machining


Our team will review for castability using the latest software to ensure the part comes out of the mold exactly how you want it.

Whether it’s 3D printed tooling, or conventional pattern and tool making, we can sample your castings and machine them quickly.

“V” Process is an innovative form of sand casting that utilizes very fine, dry sand without binders, held in shape by vacuum packing the sand between sheets of thin plastic film.

The vacuum-packed sand mold becomes hard much like a store-bought brick of coffee. This mold cavity is formed around the pattern equipment.

The results are:

  • Thin walls
  • Cosmetically smooth surface finish
  • Premium tolerances that are twice as accurate as sand casting
  • Vertical walls with zero-degree draft angles
  • Excellent reproduction of as-cast details


Pattern tooling is made of RenShape Polyurethane. Tooling modifications are quick and easy. Our patterns also have an unlimited tooling life because the sand touches the plastic film and not the actual pattern.

With order quantities as low as 5 or as many as 2000 per year, all castings can be supplied machined, finished, and ready to assemble.

"V" Process Casting

Permanent Mold Casting

Reliably consistent parts cast using gravity, tilt pour, or low pressure processes.

Best suited for medium to high volume castings. We cast a wide variety of aluminum alloys and produce parts with optimal mechanical properties.

Permanent mold castings produce a denser casting compared to pressure die castings.

Tooling for permanent mold costs less than that of die casting.

Secondary mold elements such as preformed sand cores and steel slides can be used to make more complex shapes.

All castings can be supplied machined, finished, and ready to assemble.

Prove your design and enable modifications quickly. Plaster mold casting is an excellent bridge to high-volume production processes such as die casting.

The plaster mold casting process uses plaster to form a clean, smooth, detailed mold. This process is ideal for your more intricate and/or thin-walled castings.

When compared to sand casting processes, plaster molding allows for:

  • Tighter tolerances
  • Thinner-wall capabilities (as low as .080”)
  • More detail
  • Smoother surface finish
  • Less machining required


Plaster mold casting can also be used for low-volume production, yielding up to 1000 parts per year. Tooling lead times are typically 2-4 weeks.  All castings can be supplied machined, finished, and ready to assemble.

Plaster Mold Casting

Die Casting

Low-cost unit price solution for complex parts in aluminum, zinc, or magnesium.

Die casting produces complex shapes with closer tolerances and with thinner walls than other casting methods, and much stronger than plastic injection molded parts with the same dimensional accuracy.

Appropriate for high volume production, die casting tooling produces many thousands of consistent castings.  Typical volume is 3,000 to 50,000 pieces annually. 

Automation and robotics are used to ensure the casting process is repeatable. Molten metal is injected into tool steel dies under high pressure, resulting in as-cast surfaces that are smooth with fine details.

All die castings can be supplied machined, finished, and ready to assemble.

Low tooling and part costs for a variety of shapes and sizes. Sand casting is the most widely used casting method.

Sand casting is versatile with low setup costs.

Sand molds are made from various types of sand and binders. The tooling is made using fabricated or machined patterns. Additive manufacturing processes can also be used.

Sand casting allows for:

  • Simple or complex shapes
  • Large or small parts
  • Low-cost tooling
  • Short lead times, samples in 3-4 weeks.
  • A wide variety of alloys are available


Because of these features, sand casting is well suited for making low and medium volume production castings and converting welded parts or hog-outs to castings. All castings can be supplied machined, finished, and ready to assemble.

Sand Casting

Investment Casting

Produce complex shapes in ferrous and non-ferrous alloys that would be difficult or impossible with other casting methods.

Investment casting is often referred to as “Lost-Wax” casting. This technique is used to accurately cast metals using plaster or ceramic molds. Wax patterns are “invested” in mold materials and then melted away to leave a cavity.

Investment casting is ideal for creating precise components with unique shapes that require tight tolerances, smooth surface finishes and fine detail.  This often reduces the need for secondary operations.

Investment casting is highly versatile because you can combine multiple wax patterns to create complex shapes. This allows part configurations that could not be made with other casting or manufacturing methods.

All castings can be supplied machined, finished, and ready to assemble.

We offer comprehensive sheet metal fabrication capabilities that include automated sheet handling, blanking, forming, and powder-coat finishing.

Added value includes hardware installation, finishing, and turnkey assembly. Design assistance, prototyping, low or high-volume production available.

Using state of the art equipment, our capabilities include the following:

  • Automated CNC Blanking
  • Automated CNC Laser Cutting
  • Robotic CNC Bending
  • Extensive welding 
  • Hardware and Assembly
  • Powder Coating / Painting and Silk screening
  • Design Assistance and CAD
  • Project and Inventory Management

Sheet Metal Fabrication

Plastic Thermoforming

Custom thermoformed plastics using vacuum-forming, pressure-forming, or both. Full service plastic fabrication based on the needs of your project.

Extruded plastic sheets are heated to specific forming temperatures and formed to the shape of the mold. The plastic is pulled into the tool using vacuum, pressed against the mold using air-pressure, or to achieve more complex shapes sometimes both.

Using a fully-automated process, sheets are automatically loaded, heated, and formed. Trimming operations are also CNC controlled to ensure precise parts every time.

Thermoforming uses less tooling and has lower up-front investment compared to other plastic molding processes like injection molding.

We can produce thermoformed parts up to 7ft. x 11ft. x 40in. depth.

We also offer rotational molding, drape forming, CNC fabrication / trimming, in-house painting and finishing, sonic welding, riveting, eyeleting, and soldering.