Our services

Design

Our technical expertise combined with the best three-dimensional design and artistic modeling programs allows us to translate our clients’ ideas into detailed technical projects. We are able to respond promptly to any type of request:
• 2D/3D design
• Feasibility and budget studies
• External design support
• Assistance in the development of prototypes

Co-design

We design with and for the customer with the aim of making the idea achievable. In this initial phase we release the 2D and 3D project, in order to proceed with careful validation.
We create multiple versions to finally get to the approval phase by the customer. Thanks to the speed, problem solving and know-how acquired over time, we are able to guarantee high levels of service quality.

Prototyping

We have a sophisticated rapid 3D prototyping system that allows us to create high-definition models even of small dimensions.
We offer:
• Pre-Production Modeling: we develop the model before moving on to the mass production phase, to allow the customer to test the quality of our project.
• Third Party Prototyping: we are also able to prototype on the basis of 3D files sent to us.

Creation of Moulds

We closely and carefully follow the creation of the mould, we believe that it is essential to transfer the best possible quality to the product, minimizing the waste.
In this decisive phase, the mould is carefully studied to avoid unsuitable productions, preventing the product from being damaged.
We analyze the heat fluxes, the withdrawals of the material and the extractions, all the variables that can reduce waste from the beginning and optimize the final result.
The moulds are kept in the warehouse inside the mould holder and careful maintenance is carried out periodically to ensure their durability.

Zamak Die Casting

Our machinery is made up of hot chamber presses ranging from 20 to 80 tons, by means of which we can produce high definition parts even of very small dimensions: our capacity varies, in fact, from 0.1 gr to 1 Kg. We are specialized in large series production, but we can also carry out small targeted productions. Furthermore, we have an injection control system that allows us to check the perfection of all the parameters set in real time, in favour of a high and constant quality standard.

Sprue Removing

The separation of the piece from the sprue is performed in two different ways:
• Semi-automatic
• Manual, particularly suitable for delicate pieces.

Depending on the piece and the quality required by the customer, the best modality is decided. However, in both cases, a visual quality check of the pieces is performed, in order to detect holes or other types of non-conformities.

Tumbling and Deburring

The tumbling process, i.e. the smoothing of the product aimed at eliminating any residual burrs, is very important as it allows the elimination of surface defects due to previous production processes, and prepares the piece for subsequent processing.
Deburring therefore has the objective of making the obtained piece perfect and is aimed at eliminating excess material along the contours and between the joints.
It can be done:
• Manually, suitable for large or delicate pieces
• Machine by means of tumbling.

Assembly

Our company is able to proceed with the assembly of the various components, both manually and with the use of machinery and equipment specifically designed us for the purpose. The assembly phases are subjected to meticulous checks with special measuring instruments to verify-test the correct functioning of the finished piece.

Mechanical Treatments

We are also able to perform various pre/post-galvanic mechanical treatments:
• Sandblasting, suitable for subsequent painting or matt finishes
• Sanding and grinding, useful for removing any mould signs or extractor marks that must not appear on the finished piece, but which must be there because they are functional for the extraction of the piece and its correct fusion
• Manual polishing, to obtain a high quality base
• Threads on request made to measure with high precision
• Customised drilling
• Calibration of the pieces for specific tolerances not reachable from the mould
• Laser printing, both before the galvanic with deep engravings to give the effect of the logo engraved as from the mould, and in post-galvanic contrast, even with color adjustment
• Manual brushing and satin finishing

Surface Treatments

We have a wide range of galvanic colours, made both with barrel and frame, both with an aesthetic and mechanical function: shiny, mattt, antic, satin, vintage, trendy, precious.
For this process we use a network of reliable and certified suppliers, with whom we have a daily relationship. We are also able to supply nickel free colours , with related certifications, and we can also carry out the following treatments:
• Painting also in colour to the sample, both Pantone and RAL, also with metallic effect
• Electrostatic protection with chlorine/sea (salt water) resistance
• Enamelling
• 2D and 3D digital printing
• Pad printing

Assembly Tools

Cast System is able to support the customer also in the assembly phase. In addition to support and assistance in assembling the article, we offer the necessary equipment suitable for specific products, useful for customers who have to assemble the components independently, avoiding errors or post-production damage.

Packaging

Based on the type of article, the customer’s needs and the type of means of delivery, we can also create special packaging in boxes, tissue paper, blister packs, with protective electrostatic film. At the end of the production cycle, before shipping, we carry out a manual quality control, piece by piece, with particular attention to precious and delicate items.