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  • Precision Execution

Engineering Innovation Into Manufacturable Solutions

Frigate developed prototype precision casting components for OEM applications requiring direct-cast sealing grooves and high structural integrity. Using FG 250 material, the component was produced through optimized casting and machining to meet strict inspection standards. 

  • Seal grooves were produced through direct casting, ensuring dimensional stability.
  • Components were validated through RT Level-1 radiography, material certification, and heat treatment.
  • Processes were optimized to reduce blow holes and sand inclusions in groove areas.
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Category

Prototype Precision Casting Components

Industry

Industrial Equipment Manufacturing

Core Capabilities

Direct-Cast Groove Development, Casting & Machining, Radiographic Quality Validation

Country

India

Prototype Production
4200+
Prototype Production
material-icon2
FG250
Material Integrity
Quality Assured
RT Level-1
Radiographic Quality
Defect Reduction
99%
Defect Reduction
  • Prototype Manufacturing

Customer Key Challenges

Delivering precision prototype casting components required overcoming key manufacturing and quality validation challenges, particularly for direct-cast groove geometry and internal casting integrity. 

Radiographic Quality Compliance

Achieving RT Level-1 radiographic quality in sand casting was challenging due to the risk of internal defects such as blow holes and inclusions. 

Surface Integrity in Critical Areas

Maintaining clean groove surfaces free from sand inclusions and casting defects was critical to ensure proper sealing performance and assembly reliability. 

1

Requirement Analysis

✔ Defined technical specifications based on OEM requirements for direct-cast sealing grooves and structural integrity. 

✔ Prepared design drawings, material selection (FG 250), and prototype plans to support casting feasibility and inspection compliance. 

 

2

Design & Engineering

✔ Analyzed and selected suitable casting methods to achieve grooves directly through casting instead of machining. 

✔ Optimized part geometry and casting parameters to minimize defects and maintain dimensional accuracy in groove areas. 

 

3

Manufacturing & Quality Assurance

✔ Manufactured components using controlled casting and precision machining processes to achieve required dimensional accuracy. 

✔ Performed RT Level-1 radiographic testing, material certification, and heat treatment validation to ensure casting integrity. 

4

Validation & Delivery

✔ Verified prototypes through radiographic inspection and quality checks to confirm compliance with customer requirements. 

✔ Delivered validated prototype components along with inspection documentation and material test reports. 

  • Execution Process

Execution Process

We followed a structured manufacturing and validation process to develop prototype precision casting components while meeting requirements for direct-cast groove geometry, radiographic quality, and material integrity. 

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Other Locations

  • Bhilai
  • Chennai
  • India
  • Germany
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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Other Locations

  • Bangalore
  • Chennai
  • India
  • Germany
Become a Frigatian
Become a Supplier

GENERAL ENQUIRIES

  • +91 96778 64606
  • manufacture@frigate.ai
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