01

Engineering

Engineering Design and Casting Development

AvioCast’s engineering team has extensive experience in aluminum alloy casting development, manufacturing, and simulation analysis. From design recommendations and 3D modeling to casting simulation and tooling design, we help customers improve castability, quality stability, and development efficiency.

• Provide casting design recommendations to improve manufacturability.
• Create 3D digital models based on 2D drawings.
• More than 20 years of casting simulation experience, including filling, solidification, casting quality, and mechanical property prediction.
• In-house design of sand molds, core boxes, wax injection dies, heat-treatment fixtures, positioning fixtures, inspection fixtures, straightening fixtures, pressure-test fixtures, and machining fixtures.
• Wax printing and FDM printing capabilities, integrated with SLA and 3D sand-printing supply chains to provide rapid prototype casting services.

02

Investment Casting

Complex Aluminum Alloy Investment Casting

AvioCast specializes in the engineering and production of complex, high-quality aluminum alloy investment castings. We have provided investment casting services for critical aerospace components across multiple aircraft platforms, particularly for applications requiring high precision, complex geometry, and thin-wall structures.

• Automated shell-building system.
• Available alloys include A356, A357, F357, C355, and AlSi7Cu1.5Mg.
• Maximum casting size: 16 × 18 × 25 inches, approximately 406 × 457 × 635 mm.
• Minimum wall thickness: 0.060 inches, approximately 1.5 mm.
• Capable of producing castings with multiple soluble wax cores and ceramic cores.
• Supports SLA-formed and 3D-printed wax patterns for rapid prototype casting.

03

Sand Casting

Aerospace-Grade Structural Sand Casting

AvioCast has long provided structural sand castings for the aerospace industry. Applications include gearbox housings, oil tanks, scroll housings, engine mounts, and other components requiring large dimensions, complex flow passages, and high reliability.

• Chemically bonded sand mold and core processes for thin-wall castings with complex internal passages.
• Low-pressure casting systems improve casting quality and process stability.
• Key processes, including heat treatment, radiographic testing, penetrant testing, welding, material testing, and surface treatment, can be completed in-house.
• Available alloys include A356, A357, F357, C355, 354, and AlSi7Cu1.0Mg.
• Maximum casting size: 30 × 35 × 60 inches, approximately 760 × 890 × 1,520 mm.
• Minimum wall thickness: 0.100 inches, approximately 2.5 mm.
• Capable of producing castings with multiple and complex internal sand cores.
• Supports rapid prototype casting using 3D-printed sand molds.

04

Heat Treatment

Aerospace-Standard Heat Treatment

AvioCast maintains strict control over heat-treatment processes to ensure aluminum alloy castings meet aerospace requirements for mechanical performance, dimensional stability, and quality consistency.

• Heat-treatment processes comply with aerospace standards and are Nadcap accredited.
• Straightening is performed by skilled operators after quenching.
• Optical scanning is used for dimensional verification, ensuring repeatability and process quality.

05

Surface Treatment

In-House Surface Treatment and Chemical Processing

AvioCast operates in-house chemical processing, cleaning, and painting facilities. A broad range of surface treatment services is available in accordance with aerospace standards and customer requirements to improve corrosion resistance, wear resistance, and appearance.

• Sulfuric acid anodizing.
• Chromic acid anodizing.
• Hard anodizing.
• Chemical conversion coating.
• Aqueous degreasing.
• Acid and alkaline chemical milling.
• Primer and topcoat application.
• An in-house chemical laboratory performs solution analysis, abrasion resistance testing, wet tape adhesion testing, coating weight and thickness testing, salt-spray corrosion testing, fluorescent penetrant water-content testing, and fluorescence testing.

06

Precision Machining

Engineering Design and Casting Development

AvioCast’s engineering team has extensive experience in aluminum alloy casting development, manufacturing, and simulation analysis. From design recommendations and 3D modeling to casting simulation and tooling design, we help customers improve castability, quality stability, and development efficiency.

• Provide casting design recommendations to improve manufacturability.
• Create 3D digital models based on 2D drawings.
• More than 20 years of casting simulation experience, including filling, solidification, casting quality, and mechanical property prediction.
• In-house design of sand molds, core boxes, wax injection dies, heat-treatment fixtures, positioning fixtures, inspection fixtures, straightening fixtures, pressure-test fixtures, and machining fixtures.
• Wax printing and FDM printing capabilities, integrated with SLA and 3D sand-printing supply chains to provide rapid prototype casting services.

07

Assembly

One-Stop Services from Casting and Machining to Surface Treatment and Assembly

AvioCast provides integrated services covering casting, machining, chemical processing, and hardware installation, helping customers reduce supply chain complexity while improving delivery efficiency and quality consistency.

• Dimensional control can be performed during machining and chemical milling.
• Experienced technical personnel perform a wide range of hardware assembly operations.
• Assembly capabilities include bearings, bore roller burnishing, bushings, fillet sealing, pins, plugs, restrictors, screws, studs, and threaded inserts.
• Integrated process services help customers simplify outsourcing and supply chain management.