Table of Contents
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Investment casting is widely used to create precise metal components with minimal machining, material waste, and energy. It is a very useful method to make highly intricate metal parts for various applications. The process of investment casting involves creating wax patterns replicating the shape of the final casting with the help of a die, coating the pattern with a ceramic shell, melting out the wax, and pouring molten metal into the ceramic mould. Once the molten metal cools and solidifies, the ceramic mould is broken to obtain the finished metal casting.
Indian investment casting industry generated a revenue of USD 634.1 million in the year 2022, which is expected to reach USD 1019.4 million in the year 2030, thereby registering a CAGR of 6.1% in the 2023-2030 period.
Major Variations
The investment casting process comprises some basic steps like wax pattern creation, pattern assembly, ceramic shell moulding, dewaxing, metal pouring, shell removal, and finishing. However, Investment casting companies India employ a number of variations to the investment casting process. These include sodium silicate process, silica sol process, 3D printing integration, and lost-foam casting.
The sodium silicate process involves the addition of sodium silicate to the sand in order to make a slurry, which is used to form the ceramic mould for receiving molten metal. This process is commonly used to create high-temperature moulds and shell heavy components. Since sodium silicate dissolves in water, it can be easily cleaned and removed.
Silica sol process is widely preferred to make high-precision castings required in industries like aerospace and medical due to higher dimensional accuracy and superior surface finish. This process involves the addition of a colloidal solution of silica particles in water to the refractory slurry for making a low-viscosity and fine-grained ceramic mould.
The lost foam process involves the creation of a foam pattern, instead of a conventional wax pattern, to make a mould for the casting. The foam pattern is coated with a refractory material and placed in a box or flask. When the molten metal is poured into the mould, the foam pattern evaporates, leaving behind the metal casting. This process is usually employed to cast components with complex geometries.
3D printing is being employed by multiple investment casting companies in India. The utility of 3D printing in investment casting is in creating patterns that enable the production of highly complex parts while reducing tooling lead time and cost.
Applications and Materials
Investment casting companies in India serve a number of industries. However, there are specific industries that are driving the growth of the investment casting market in the country. The automobile industry is a major growth driver due to increasing vehicle production, which, in turn, is fuelling the demand for lightweight and complex components. Rapid growth of the aerospace industry in India is also boosting the investment casting industry due to rising demands for various kinds of high-strength aircraft components.
Indian investment casting companies work with a number of materials. These include, but are not limited to, stainless steel, carbon steel, nickel and cobalt-based super-alloys, non-ferrous metals like brass and aluminium alloys.
Landscape
Indian investment casting landscape features around 17 specialised manufacturers and a network of about 4500 foundries. Rajkot in Gujarat is a major hub of investment casting in the country, with more than 110 investment casting units producing over 160 tonnes of investment castings each day.
Maharashtra is another key state in the investment casting landscape of India. Other major states with a significant contribution to the investment casting industry are Karnataka and Tamil Nadu.
Conclusion
India is the fastest-growing investment casting market in the Asia-Pacific region. Investment casting is witnessing multiple advancements, like 3D-printed patterns and advanced materials.
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