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Die Casting

KBR is a reliable die-casting service provider specializing in various metal casting services, including lost foam casting, investment casting, sand casting, high-pressure die casting, etc., for the manufacturing industry.

Our high-pressure die casting and gravity casting services are tailored to the client’s project needs or parts specifications. We usually use non-ferrous alloy material (zinc, copper, aluminum, or magnesium) for die casting to ensure high dimensional stability. Our capabilities and die-casting infrastructure include,

Aluminum Die Casting

At KBR, we specialize in many aluminum die-casting alloys, including aluminum-silicon, aluminum-zinc, aluminum-tin, aluminum-magnesium, aluminum-copper, aluminum-iron, and aluminum-nickel.

Our aluminum die-casting services help achieve textured or smooth surfaces and empower our clients with the ability to produce sophisticated parts. Additionally, our quality of aluminum die casting helps increase corrosion-resistant parts and assemblies and highly robust and lightweight components.

Investment Casting

At KBR, we offer investment casting services featuring an organized process. It involves creating the pattern, building the tree, making the shell, removing the wax, casting the metal, removing the shell, finishing, and inspecting the parts. Our investment casting services aim to deliver incredible dimension accuracy, metal compatibility, smooth surface finishes, and flash-free parting lines. Thus, as a manufacturer of components, our investment casting process contributes to your ability to produce sophisticated parts.

Our manufacturing setup hosts state-of-the-art equipment, including advanced robotic arms to achieve remarkable accuracy and finishing. We cast metals to support manufacturing cylinder heads, pistons, crankshafts, calipers and discs, braking systems, gearbox components, and more. Please take a look at our investment casting infrastructure and capabilities.

Looking for more insights into our investment casting capabilities and process? Email us at info@kbrsourcing.com to connect with our experts.

Lost Foam Casting

Also known as LFC, lost foam casting helps create complex metal parts wherein molten metal evaporates a foam mold held still with sand. Our process begins with a polystyrene foam to carve, machine (from a foam block) or create a mold material. Further, it involves heating beads of polystyrene in an aluminum die to expand and fill it. Later, we cover the polystyrene foam mold with a ceramic refractory coating, in which the foam mold is placed and that also serves as an obstacle disallowing foam and sand from mixing.

We deliver the following advantages with our LFC process.

  • Reduced lead time
  • Lowered production cost
  • Creation of highly complex shapes with versatile properties

Our LFC Capabilities

KBR is a reliable die-casting service provider specializing in various metal casting services, including lost foam casting, investment casting, sand casting, high-pressure die casting, etc., for the manufacturing industry.

Please email us at info@kbrsourcing.com for more insights into our LFC process and support.

Permanent Mold Casting

At KBR, while adhering to the best permanent mold casting practices, our process enables high production rates and reusability of the mold. Our automation-driven production approach helps manufacturers produce complex shapes quickly and economically. We optimize these benefits for our clients with our capabilities, including the following.

Looking for a permanent mold casting partner? Please email us at info@kbrsourcing.com and allow our experts to connect with you for an in-depth discussion.

Sand Casting

At KBR, sand casting constitutes a vital part of metal casting expertise. We support the manufacturing sector with sand casting services to enable manufacturers to produce engine parts with incredible pressure tightness, accurate machinability, robust structure, and low weight.

Our sand casting undergoes an extensive process. The steps include,

  • Creating a mold pattern and a gate system
  • Placing the mold pattern in the sand and packing it around the mold
  • Removing the pattern to form a cavity
  • Heating the metal to a high temperature
  • Pouring the molten metal into the cavity
  • Separating the sand mold along a parting line
  • Destroying the mold cavities

We use many components during the process including patterns, molds, risers, pouring cups and sprue, cores, molding flask, and a gating system. Our clients choose us for precision, stringent quality checks, and production infrastructure that enables us to deliver the desired outcomes. However, partnering with us lets you optimize benefits like shorter lead times and significant cost savings for low-volume production. Here’s more to what we offer.

Need sand casting support for your manufacturing setup? Please connect with us at info@kbrsourcing.com and explore more about our sand casting expertise.

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