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

  • A person in a blue shirt looking at a blueprint in a workshop filled with various camera equipment.

    1. Reverse Engineering

    We 3D scan your casting to precisely recreate the model for legacy or undocumented parts.

  • Illustration of a young man working at a desk in an office with large window view of city skyline and skyscrapers; desk has computer monitor and potted plants.

    2. Submit Your CAD or Concept

    Submit your CAD design
    or concept for our team
    to review and assess.

  • An animated man in a blue suit sitting at a wooden desk with a computer monitor in a bright office. The office has large windows showing a city skyline with tall buildings and partly cloudy sky. There are green potted plants on either side, and a few office supplies on a side table.

    3. Intro Call & Quote

    We review your goals, provide a tailored quote, and answer any technical or timeline questions.

  • Cartoon man with brown hair, glasses, and a blue shirt sitting at a desk with a laptop, in an office with framed documents on the wall, potted plants, and a water cooler.

    4. Submit Purchase Order

    Once approved,
    your project moves into
    the production phase.

Phase 2: Engineering & Production

  • An animated person with glasses, wearing a hat, sits at a desk working on a computer in a storage room with shelves of boxes.

    5. Engineering Review & Simulation

    Our team validates and optimizes your part using CAD and flow/solidification modeling.

  • Colored stress analysis simulation of a metallic mechanical part showing different stress regions, with a 3D coordinate system and graphs in the background.

    6. Mold & Core Design

    We engineer and simulate the mold for performance, cost-efficiency, and reliability.

  • Two orange robotic arms working in an industrial facility with machinery and equipment.

    7. Robotic 3D Printing (RoboCast)

    Our ABB robots 3D print your core or mold directly from the model — no patterns needed.

  • An animated cartoon of a blacksmith working with molten metal in a forge, wearing gloves and a blue apron.

    8. Metal Pouring

    We pour your chosen alloy under tightly controlled conditions, ensuring material integrity and precision.

Our Process

Phase 3: Quality & Delivery

  • A person operating a vintage aircraft's control wheel with a telescope, with clouds visible through the cockpit window and a screen above.

    9. Cleaning & Laser Scanning

    Parts are cleaned and inspected via FARO scanners and/or CMM tools. Inspection reports available upon request.

  • Illustration of a person in a cap sitting in a high-tech control room with screens, machinery, and monitoring equipment, with a robotic arm in the background.

    10. Quality Control

    If required, mechanical testing, dimensional reporting, or non-destructive testing (MPI/LPI) is completed.

  • Person inspecting cargo at shipping and logistics warehouse with forklift and trucks

    11. Shipping & Logistics

    We handle packaging and delivery with full traceability and documentation.

Inside a metal workshop, workers are operating furnaces and machinery, with glow from heated metalwork illuminating the space.

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