We constantly focus on providing exceptional product & casting solutions for a wide range of industries, Heritage and Restoration Services.
Although we’re specialists in small-scale projects we also offer large-scale casting runs for clients nationally and internationally. With our years of experience, expertise and state-of-the-art facilities, we ensure that your casting requirements are always met with precision and excellence…period!
Metal Casting
Our skilled team of casting professionals constantly utilises state-of- the-art techniques and technologies to always deliver the very best metal casting services. Whether you need investment casting, sand casting, or die casting, we certainly have the capabilities to fulfil your specifications. From matching heritage items for restoration, defining highly intricate components or producing complex geometries, we can always handle diverse casting needs with a meticulous attention to detail.
Material Selection
We understand that different projects require different materials. As well as a quality cast iron product we also offer an extensive selection of high-quality alloys, including aluminium, brass, bronze, stainless steel, and more. Sonny Chema ( 1910’s Head of Production) can guide you in choosing the most suitable material that meets your project requirements in terms of strength, durability, and cost-effectiveness.
CORE10
Core10 steel sheeting is renowned for its durability and longevity. The natural patina that forms on the surface acts as a protective layer, shielding the underlying steel from corrosion. This unique characteristic makes Core10 sheets an excellent choice for various applications, including heritage restoration, architectural facades, landscaping features, sculptures, and much more. By opting for Core10 sheets, you also contribute to sustainable design practices, as weathering steel is a low-maintenance and environmentally friendly material.
Prototyping and Customisation
We take pride in our ability to assist you throughout the entire casting process, from initial design to final production. Our team of engineers and designers collaborate closely with you to develop prototypes or matching lost existing designs. We also provide valuable insights for optimising and customising your product design. With our commitment to customisation, we ensure that your casting solutions are tailored to your unique needs and specifications.
CAD CAM Software
At 1910 our cutting-edge foundry solutions help to streamline design-to-production processes seamlessly. With intuitive CAD tools, we can conceptualized and refined intricate designs with ease, while our advanced CAM features ensure a precise translation of any designs into clear manufacturing instructions. While our CNC machining, 3D printing, streamlined manufacturing processes and optimised toolpaths constantly reduces production times, and greatly improves overall productivity. Whu not experience the future of manufacturing with 1910’s CAD CAM Software, where innovation converges with precision to redefine what’s possible in the realm of design and production.
3D Printing
We also offer comprehensive 3D Metal Printing as a Service, tailored to meet your manufacturing needs with unparalleled precision and efficiency. Our state-of-the-art facilities and experienced staff will work with you to seamlessly transform your concepts into reality.
Pattern Making
Our pattern-making software redefines traditional processes, offering a digital platform where creativity seamlessly merges with precision.
Wether you’re re creating a heritage piece or intricate machine patterns, it’s now a lot easier using our intuitive design tools to optimise and refine every detail. From apparel to industrial applications, our software enhances efficiency and accuracy, ensuring your patterns are translated flawlessly into physical reality.
Experience a new era of pattern-making with The 1910 Foundry, where innovation and craftsmanship come together under one roof to deliver endless possibilities in design and production.
A SMALL BOUTIQUE FOUNDRY?
At the 1910 Ironworks, we offer small-scale production with end-to-end support, from CAD design and material selection to the final production of the finished product. We also guarantee exceptional quality, realistic lead times, and cost-effective solutions for prototyping, specialisation or heritage components.
CASTING -Our Process
What is Gravity Die Casting?
Gravity Die Casting is a permanent mould casting process, where the molten metal is poured from a vessel or ladle into the mould. The mould cavity fills with no force other than gravity, filling can be controlled by tilting the die. Undercuts, and cavities can be incorporated into the component form with the use of sand cores. This process gives a better surface finish than sand casting as well as better mechanical properties, both due to rapid solidification.
Investment Casting Process
Investment casting employs a shell made of ceramic, plaster, or plastic that is formed around a wax pattern. The wax pattern is melted and removed in a furnace and metal is poured into the shell to create the casting.
1. Creating the Pattern
It utilises a pattern with the same details as the finished part, except that there is an allowance for thermal contraction (i.e. shrinking). Patterns are typically made of wax using a metal injection die.
2.Mounting The Wax Patterns And Creating The Tree
Once a wax pattern is produced, it is assembled with other wax components to form the gate and runner metal delivery system. Depending on the size and configuration of the desired finish component, multiple wax patterns may be processed using a single tree.
3.Creating The Mould Shell
The entire wax pattern assembly is dipped in a ceramic slurry, covered with sand stucco, and allowed to dry. Cycles of wet dipping and subsequent stuccoing are repeated until a shell of the desired thickness is created. That thickness is partly dictated by product size and configuration. Once the ceramic shell has dried, it becomes sufficiently strong to retain the molten metal during casting.
4.Wax Removal
The entire assembly is placed in a steam autoclave to melt away most of the wax. Any remaining wax soaked into the ceramic shell is burned out in a furnace. At this point, the residual wax pattern and gating material have been completely removed and the ceramic mold remains with a cavity in the shape of the desired cast part. This high-temperature operation also increases the strength and stability of the ceramic material. In addition, it helps to minimize the reaction of the shell and metal during pouring.
5.Melt And Cast
The mould is preheated to a specific temperature and filled with molten metal, creating the metal casting. Nearly any alloy can be produced using this process. Either air melting or vacuum melting may be employed as dictated by the alloy chemistry. Vacuum melting is utilised mainly when reactive elements are present in the alloy.
6.Final Operations
Once the casting has cooled sufficiently, the mould shell is broken away from the casting in a knockout operation. The gates and runners are cut from the casting, and if necessary, final post-processing sandblasting, grinding, and machining is performed to finish the casting dimensionally. Non-destructive testing may include fluorescent penetrant, magnetic particle, radiographic, or other inspections. Final dimensional inspections, alloy test results, and NDT are verified prior to shipment.
Quality Assurance
At the 1910 Ironworks, quality is our top priority. We adhere to rigorous quality control standards at every stage of the casting process, and to ensure the production of flawless components for all our clients every time.
To make sure this happens the 1910 has a very hands on approach to material and performance testing, employing advanced measurement and production techniques to guarantee the integrity and precision of all our final cast products.
Working towards Carbon-Free Green Steel
Our aim and mission at 1910 is to revolutionise metal and steel production That’s why we have an unwavering dedication to environmental responsibility, while spearheading an ambitious initiative to develop green steel that leaves little or no carbon footprint!!
By seamlessly integrating renewable energy, circular economy principles, and innovative collaboration, 1910 is working towards redefining the metal and steel industry’s landscape, setting examples for a more sustainable and eco-conscious future.
To find out more about our foundry and casting facilities – please contact Steve via the contact me page or call 0402481461