Expocet Ltd is a specialist provider of high-quality Investment Castings, often referred to as the Lost Wax Process. This manufacturing method is the industry standard for producing intricate, thin-walled components with exceptional surface finishes and tight dimensional tolerances.

By utilising investment casting, we enable our clients to achieve "near-net-shape" parts, significantly reducing or even eliminating the need for costly secondary machining operations.

Technical Capabilities & Material Range

Our investment casting services cover a vast array of ferrous and non-ferrous materials, catering to high-performance and safety-critical applications.

• Casting Weight Range: 0.05kg – 100kg

• Materials Cast:

  • Stainless Steels: 304, 316, and Duplex grades for superior corrosion resistance.

  • Carbon & Alloy Steels: For high-strength structural applications.

  • Aluminium Alloys: Lightweight solutions for aerospace and automotive sectors.

  • Super Alloys: Nickel and Cobalt-based alloys for extreme thermal environments.

• Production Volumes: Highly flexible, ranging from small batches to high-volume series production.

The Investment Casting Advantage

Investment casting is the preferred choice for engineers seeking complexity without compromising on quality:

• Exceptional Surface Integrity: Achieve superior surface finishes (typically 3.2 microns or better) compared to traditional sand casting.

• Complex Internal Detail: The use of ceramic cores allows for the creation of intricate internal galleries and complex cooling channels.

• Tight Dimensional Tolerances: Consistent repeatability of +/- 0.1mm per 25mm, ensuring high-precision assembly.

• Material Versatility: Capability to cast almost any metal, including those difficult to machine or forge.

Value-Added Engineering & Finishing

To provide a complete "ready-to-fit" component, Expocet manages a full suite of post-casting services:

• Rapid Prototyping: Utilising 3D-printed wax patterns for rapid design verification before hard tooling.

• Heat Treatment: Specialised processes including annealing, tempering, and solution treating to enhance mechanical properties.

• Precision Machining: CNC finishing for features requiring ultra-tight tolerances.

• Surface Treatments: Electropolishing, passivating, plating, and specialized coatings.

• Non-Destructive Testing (NDT): Including X-ray, Magnetic Particle Inspection (MPI), and Dye Penetrant testing to ensure internal integrity.

Industry Sectors Supplied

Our investment castings are trusted in sectors where failure is not an option:

• Aerospace & Defence: Turbine blades, fuel system components, and structural brackets.
• Medical: High-precision surgical instruments and orthopaedic implants.
• Oil & Gas: Corrosion-resistant valves, pumps, and drilling equipment.
• Automotive: Turbocharger wheels, high-performance engine parts, and EGR components.
• Food & Pharmaceutical: Stainless steel components requiring high hygiene standards and smooth finishes.