Advanced, Latest-Generation Investment Casting Production Facilities
80 Tons/Month Capacity • 300kg New-Gen Inductotherm Melting • 6-Arm Shell Dipping Robot • 1200°C Duplex Heat Treatment
Advanced foundry infrastructure engineered to deliver an elevated manufacturing experience for global OEMs: powered by 300 kg new-generation Inductotherm induction melting, a 6-arm dipping robot for peak ceramic shell production efficiency, and automatic heat treatment furnaces with precision temperature control up to 1200°C suitable for Duplex Stainless Steel. Supported by heavy-duty infrastructure to cast large investment casting components up to 800 mm (W) × 1200 mm (L) and unit weights up to 100 kg.
Advanced Wax Injection with Micro-Temperature Control
High-precision hydraulic wax injection machines with PID micro-temperature regulation (±0.5°C) maintain consistent wax viscosity, eliminating volumetric pattern shrinkage, air entrapment, and cavitation.
- ✔ Micro-temperature PID control (±0.5°C)
- ✔ Multi-cavity high-precision aluminum dies
- ✔ Uniform dimensional repeatability across high-volume production
6-Arm Dipping Robot for Ceramic Shell Production Efficiency
Automated 6-arm industrial dipping robots perform synchronized immersion in colloidal silica slurry and fluidized bed ceramic stuccoing. This maximizes daily shell production efficiency while ensuring uniform ceramic mold thickness, eliminating thin corners and casting inclusions.
- ✔ 6-arm robotic dipping carousel maximizing mold output & cycle consistency
- ✔ Fluidized bed zircon and mullite ceramic sand application for high-integrity shells
- ✔ Climate-controlled drying tunnels with monitored RH and temperature
300kg New-Generation Inductotherm Induction Melting Furnace
Equipped with 300 kg new-generation high-frequency induction melting systems from Inductotherm. Electromagnetic bath stirring ensures rapid, homogeneous alloy melting with zero cross-contamination and strict chemical control across stainless steels and superalloys.
- ✔ 300 kg new-generation Inductotherm induction crucible
- ✔ Homogeneous electromagnetic bath stirring preventing alloy element segregation
- ✔ Submerged optical pyrometry for precise tapping temperature control
Automatic Heat Treatment Furnace (Up to 1200°C) for Duplex Stainless Steel
Fully automated PLC-controlled heat treatment furnace with precision temperature regulation up to 1200°C. Engineered specifically for solution annealing and optimal ferrite-austenite phase balance in Duplex and Super Duplex Stainless Steels (e.g. 2205, 2507).
- ✔ Controlled temperature up to 1200°C with automated PLC cycle management
- ✔ Specialized solution annealing & rapid water quenching for Duplex Stainless Steel
- ✔ Calibrated time-temperature chart recording for EN 10204 3.1 certification
Heavy Equipment for Large Castings: Up to 800 mm (W) × 1200 mm (L) & 100 kg
While conventional foundries are restricted to small casting envelopes, PT ZAP has engineered large-scale dipping stations, heavy-duty mold handling, and induction pouring infrastructure capable of producing single-piece investment castings up to 800 mm width × 1200 mm length with finished unit weights up to 100 kg.
Robotic Shelling & Ceramic Mold Building in Action
PT ZAP Plant • Automated Shelling Facility
Robotic Shell Dipping
Dual-arm robotic manipulators dipping wax trees into colloidal silica slurry.
Precision Slurry Immersion
Even primary slurry coating ensuring zero bubble adhesion on intricate details.
Sand Stuccoing Raining
Fluidized bed sand stucco application creating high-strength ceramic molds.
Automated Conveyor Line
Multi-tier climate-controlled drying conveyor maintaining optimal shell curing.
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Precision Casting & CNC Machining Quotation Wizard
Receive a direct factory proposal for lost-wax casting & 100% CNC finished parts within 24–48 hours.
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