New Zealand

Malabou Limited

4/13, Gumfield Drive, Warkworth

Auckland 0910, New Zealand

Email:admin@malabou.com


Australia

Malabou Pty Limited

Level 11, 1 York Street Sydney

NSW 2001 Australia

Email:admin@malabou.com


India

Malabou Testing & Services India Pvt Ltd

738/2C, A P Ind Park,

Goldwins, Avinashi Road

Coimbatore, 641014

Email:admin@malabou.com

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For Enquiry

+64 09 2710038

Working Hours

We are happy to meet you during our working hours. Please make an appointment.

  • Monday-Friday: 9am to 5pm
  • Saturday: 10am to 3pm
  • Sunday: Closed



Fabrication to Casting Conversion

Converting fabrications to castings can offer a competitive advantage by improving production efficiency, reducing costs, and allowing for more complex and higher-quality products.


Here are some of the key benefits of converting fabrications to castings:

Cost Reduction

 Lower Material Costs: In casting, a mold is created, and the material is poured into it, potentially reducing waste compared to fabrication where material is cut, welded, or shaped.

 Simplified Processes: Casting eliminates or reduces multiple machining steps, welding, and assembly processes, which can often be more expensive and time-consuming in fabrication.


Design Flexibility

 Complex Geometries: Casting allows the production of more complex shapes and designs that would be difficult or impossible to achieve through traditional fabrication methods.

 Lightweight Components: Castings can be designed with scalloped or hollow sections, reducing weight without sacrificing strength.


Improved Quality and Consistency

 Reduced Human Error: Since casting is a largely automated process, the risk of human error often involved in fabrication is reduced.

 Better Tolerances: Precision castings can offer tighter tolerances and more consistency than many fabrication processes, reducing the need for further machining.


Faster Production Times

 Reduced Lead Times: Casting processes, especially for mass production, can be faster than fabrication due to fewer steps involved.

 Economies of Scale: Once a mold is created, the casting process can be repeated multiple times with minimal setup, which is ideal for large-scale production.


Material Optimisation

 Variety of Materials: Casting allows for using a wide range of alternative metal grades offering better properties such as strength, corrosion resistance, and thermal stability.


Reduced Labor Costs

 Automation Potential: Casting processes, especially modern techniques, can be highly automated, which reduces the need for manual labour and minimises labour costs.

 Less Post-Processing: Fabricated parts often require significant additional work, such as welding, grinding, and finishing. Castings often require less post-processing, saving on labour and time.


Sustainability

 Material Efficiency: The casting process generally produces less material waste compared to fabrication techniques like cutting, welding, or milling.

 Recycling: Casting processes allow for the reuse of materials, improving sustainability in production.


Better Structural Integrity

 Fewer Joints and Welds: Castings tend to have fewer joints and seams than fabricated components, which can improve the structural integrity and reduce the risk of failure at weak points, such as welds.

 Internal Strength: Cast materials can be engineered to achieve specific internal properties, such as grain structure and uniformity, contributing to better overall strength.


Minimised Assembly

 Fewer Components to Assemble: In most cases, a casting can replace a series of fabricated parts, reducing the need for assembly labour and potential for errors during assembly.

 Integration of Features: Castings can integrate multiple features into a single component, which would otherwise require separate pieces in fabrication.