Production Process

Our Craftmanship

Custodians of an ancient culture that uses traditional techniques as well as advanced, automated and manual tools, handled with the experience of our casting masters.

We are able to support architects and designers in the development and implementation of their ideas into unique objects.
We manage all the production process and cast metal from the prototype to the mold, to the final product.

Specializing in die casting of brass, aluminum and zinc alloy, we focus our production mainly to interior designers and manufacturers of lighting fixtures that assemble and electrify the various products offered.

Design Development

Design Development's team collaborate with the client to refine the design concept, create detailed CAD models based on the agreed-upon design concept. Engineers conduct feasibility studies and analysis to ensure the design is optimized for brass die casting, considering factors such as material flow, part geometry, and tooling requirements. Design Development conducts rigorous quality control inspections at various stages of the production process. Inspection techniques may include dimensional measurement, visual inspection, mechanical testing, and non-destructive testing to ensure compliance with specifications and standards.

Labs

Several specialized labs are involved to ensure the quality and integrity of the products in carrying out brass die casting projects, like: Material Testing Lab, Die Casting Facility, Quality Control and Inspection Lab, Finishing and Surface Treatment Facility, Assembly Area. These labs and facilities work in synergy to ensure that brass die casting projects for third parties are carried out efficiently, with high precision, and in compliance with industry standards and customer requirements. Collaboration between different departments and constant monitoring of processes are essential to maintain quality and deliver superior brass castings to clients.

Die Casting

In the die casting process for brass craft projects, molten brass is injected at high pressure into a steel mold cavity, replicating the intricate details of the desired component. The mold, typically made of two halves, allows for precise shaping and quick solidification of the brass. Once solidified, the mold opens, and the brass casting is ejected. After ejection, the casting undergoes trimming, deburring, and finishing processes to achieve the final desired specifications and surface quality. This method ensures rapid production cycles and high dimensional accuracy, making it ideal for mass production of complex brass components.

Lost Wax Casting

Lost wax casting is a precise method utilized in the creation of brass craft projects. The process commences with the fabrication of a pattern, typically crafted from wax, replicating the desired shape of the final brass component. These wax patterns are then attached to a sprue to form a tree-like structure. Subsequently, the entire assembly is coated with a ceramic slurry, creating a mold around the wax pattern. Once the ceramic shell has dried, it undergoes a burnout process, eliminating the wax and leaving behind a hollow cavity. Molten brass is then poured into the cavity, filling the space previously occupied by the wax pattern. After cooling and solidification, the ceramic shell is removed, revealing the brass casting, which is further refined through trimming and finishing processes to achieve the desired appearance and dimensions. Lost wax casting enables the production of intricate and detailed brass components, making it a preferred method for crafting complex brass craft projects.

Gravity Casting

Gravity casting, also known as permanent mold casting, is a straightforward process used in the creation of brass craft projects. The method involves pouring molten brass into a durable metal mold, typically made of steel or iron, with a predefined cavity representing the shape of the desired component. Gravity aids in filling the mold as the molten brass flows downward under its own weight. Once the brass has solidified within the mold, the casting is allowed to cool before being ejected from the mold. Excess material is trimmed, and finishing processes such as grinding, polishing, or machining may be applied to achieve the required surface finish and dimensional accuracy. Gravity casting offers advantages such as cost-effectiveness, high production rates, and the ability to produce components with consistent quality, making it a suitable method for manufacturing brass craft projects.

Sand Casting

Sand casting is a versatile and widely-used method employed in the creation of brass craft projects. The process begins with the formation of a mold made from sand mixed with a binding agent, surrounding a pattern representing the final shape of the brass component. Molten brass is then poured into the mold cavity, filling the space created by the pattern. After the brass has solidified and cooled, the sand mold is broken away, revealing the brass casting. The casting is subsequently trimmed to remove any excess material and may undergo additional finishing processes such as grinding or polishing to achieve the desired surface finish and dimensional accuracy. Sand casting offers flexibility in producing a variety of brass components and is particularly suitable for larger and less intricate pieces.

Mechanical Treatments

In brass die casting projects, mechanical treatments play a crucial role in enhancing the quality and precision of the final components. After the die casting process, mechanical treatments such as trimming, machining, and surface finishing are employed to remove excess material, refine dimensions, and improve surface quality. Machining processes such as milling, drilling, and tapping may be utilized to achieve intricate features or critical dimensions that cannot be achieved through die casting alone. Additionally, surface finishing techniques like grinding, polishing, or shot blasting are applied to enhance the aesthetic appearance and functional properties of the brass components, providing a smooth, uniform surface finish and improving corrosion resistance or wear resistance as needed.