Engineering-Led Solutions for Cast Component Design, Manufacturing, and Program Execution
Metal Casting Development LLC provides engineering services focused on designing cast components and manufacturing processes that work in production — not just in CAD or simulation.
Our work spans design & engineering, technical services, and program management, supporting customers from concept through production ramp-up and sustained manufacturing.
Design & Engineering Services
Design for Manufacture of Cast Components
We transform concepts into manufacturable cast components through disciplined, engineering-led design.
Our focus is on structural integrity, castability, and process robustness, ensuring designs perform reliably at production scale.
Design & Engineering Capabilities
- Cast component design and redesign (aluminum & ferrous)
- Design-for-Manufacture (DFM) and Design-for-Casting (DFC)
- Structural and stiffness optimization
- Tolerance development and GD&T support
- Material selection and specification definition
- Integration with downstream machining and coating processes
Design decisions are validated against real foundry constraints, not idealized assumptions.
Manufacturing Process Engineering
Engineering the Casting Process — Not Just the Part
We design and validate manufacturing processes that enable repeatable, low-scrap production.
Using engineering analysis, simulation, and production experience, we develop robust processes that reduce turbulence, improve feeding, shorten cycle time, and stabilize quality.
Process Engineering Services
- Gating, runner, and feeding system design
- Bottom-fill and controlled-flow strategies
- CFD-based process analysis and validation
- Solidification control and defect mitigation
- Pouring temperature, fill time, and cycle optimization
- Tooling and mold design review
Our goal is process stability, not trial-and-error correction.
Technical Services
On-Demand Engineering Support for Production Stability
Technical services support the stabilization, improvement, and recovery of manufacturing processes.
From root-cause analysis to corrective action, we provide practical engineering support grounded in manufacturing reality.
Technical Support Includes
- Process audits and technical reviews
- Root-cause analysis of casting defects
- Process correction and containment actions
- Launch support and early-production troubleshooting
- Scrap reduction and yield improvement initiatives
- On-site and remote engineering support
This is hands-on engineering — not report-only consulting.
Program Management
Engineering-Driven Program Execution
Program management integrates design, engineering, validation, and launch into a single, visible plan.
We manage casting programs with a focus on technical risk reduction, schedule discipline, and cost control.
Program Management Scope
- Program planning from concept through SOP
- Coordination between OEMs, foundries, and suppliers
- Design and process readiness tracking
- Launch support and production ramp-up
- Risk identification and mitigation
- Timeline, cost, and technical alignment
Engineering decisions remain central — program management supports them, not the other way around.
When Engineering Services Add the Most Value
- New cast component development
- Complex structural or safety-critical castings
- Programs experiencing launch delays or high scrap
- Transitions between foundries or manufacturing regions
- Cost-reduction initiatives requiring process redesign
- Programs requiring tight integration of design and manufacturing
Need engineering support for a casting program?
Whether you’re launching a new component, stabilizing production, or correcting persistent defects, we can help.
Why Metal Casting Development
- Engineering-led, not sales-driven
- Deep casting and manufacturing experience
- Focus on production-ready solutions
- Independent, objective technical support
- Practical, implementable outcomes