Our Process: From Concept to Casting
At One Off Castings, we specialize in transforming complex, one-time designs into reality. Our integrated approach combines advanced robotics, precision tooling, and decades of foundry expertise to deliver high-quality castings efficiently and reliably.
Our Process
Phase 1: Project Setup
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1. Reverse Engineering
We 3D scan your casting to precisely recreate the model for legacy or undocumented parts.
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2. Submit Your CAD or Concept
Submit your CAD design
or concept for our team
to review and assess. -
3. Intro Call & Quote
We review your goals, provide a tailored quote, and answer any technical or timeline questions.
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4. Submit Purchase Order
Once approved,
your project moves into
the production phase.
Phase 2: Engineering & Production
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5. Engineering Review & Simulation
Our team validates and optimizes your part using CAD and flow/solidification modeling.
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6. Mold & Core Design
We engineer and simulate the mold for performance, cost-efficiency, and reliability.
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7. Robotic 3D Printing (RoboCast)
Our ABB robots 3D print your core or mold directly from the model — no patterns needed.
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8. Metal Pouring
We pour your chosen alloy under tightly controlled conditions, ensuring material integrity and precision.
Our Process
Phase 3: Quality & Delivery
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9. Cleaning & Laser Scanning
Parts are cleaned and inspected via FARO scanners and/or CMM tools. Inspection reports available upon request.
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10. Quality Control
If required, mechanical testing, dimensional reporting, or non-destructive testing (MPI/LPI) is completed.
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11. Shipping & Logistics
We handle packaging and delivery with full traceability and documentation.
