One of the Foremost Precision Casting & Metal
Component Manufacturers in the Pacific Rim.

Capability

Process Capability
  • Investment (lost wax) Casting in a variety of steels and alloys
  • Rapid Prototyping
  • Lost PLA Casting
  • Component Assembly and Sub-assemblies
  • Heat Treatment and Surface Treatments and Coating, including sand and bead blasting
  • Solid Modelling, Finite Element Analysis and Design Verification
  • Design for Manufacturability and Assembly (DFMA)
  • Full Metallographic and Mechanical Testing Laboratories
  • Destructive and Non-destructive Testing
  • Full Certification and Verification for Traceability

If the customer’s design can be more efficiently manufactured using a process other than investment casting, we can assist in sourcing forged, sand and die-cast products at very competitive prices.

Investment Casting - Video
Precision Casting

Investment casting (also known as lost wax casting) is a precision casting methodology that can be used over the widest range of metal types including Stainless Steel, Medium Alloy Steels, Plain Carbon Steels, Copper Base alloys such as Brass and Bronze, Aluminium, Tool Steels and Super alloys such as Cobalt and Nickel based alloys.

It is a near net shape methodology which yields many benefits over other metal forming technologies.

Supreme manufactures castings ranging from a few grams (about 0.1 oz) in weight to about 120 kg (265 lb). The cross-sectional limits are typically 2.5 mm (0.1 in) to 75 mm (3.0 in). Typical tolerances are +/- 0.1 mm for the first 25 mm (0.005 in for the first inch) and +/- 0.04 mm for the each additional 10mm (0.002 in for each additional inch).

A standard surface finish is 1.3–4 micrometres (50–125 μin)

The advantages of investment casting are

  • Excellent surface finish
  • High dimensional accuracy
  • Extremely intricate parts are castable
  • Almost any metal can be cast
  • No flash or parting lines
  • Elimination or reduction of downstream operations such as machining significantly reducing total cost.
Design

Our in-house design department is able to combine the latest 3D CAD technology (Solidworks 2012) with a comprehensive knowledge of the casting process to assist customers to realise efficient, cost effective and reliable solutions to their requirements.

Design data can be from obtained by adapting existing legacy data such as fabrication drawings, reverse engineering from prototype samples or by working with the customer to define a specification for the requirement and creating an optimal solution that exploits the benefits of the near net shape casting process. By working closely with the customer we can add significant improvements to their bottom line.

Part or assembly simplification and the associated reduction in manufacturing steps often produce attractive cost savings. We utilise a range of design methodologies to define the metal component;

  • Design formanufacture and assembly (DFMA) – A technique to simplify the overall product structure, to reduce manufacturing and assembly costs, and quantify these improvements
  • Finite Element Analysis (FEA) – A computer based numerical method of calculating the deflection and stress of geometry under applied loads
  • Failure Mode and Effect Analysis (FMEA) – A team based procedure to analyse occurrences of failure to achieve intended functions of a part or system and rank these in terms of severity and likelihood so that controls can be implemented to eliminate or reduce these risks.  
  • Reverse engineering - using CMM surface probe scans we can produce very accurate profiles that import into the CAD software and allow very accurate models to be made, especially of freeform components (impellers etc) that are otherwise extremely difficult to measure.
  • Once geometry is determined tooling can be produced and first off components made. These can be verified with highly accurate dimensional analysis, using our Coordinate Measuring Machine or high resolution 3D laser scanning. This gives assurance that the design intent is physically realised and maintained throughout the product lifecycle.
Machining

We offer a full range of machining services to complement the range of alloys used in our casting process and deliver fully finished items or assemblies. Our expertise and process knowledge ranges from conventional computer numerically controlled machining such as milling, turning, gear cutting and grinding operations to non-conventional Spark eroding (EDM) and 3D lasercutting. Significant reductions in machining cost are achieved using the near net shape casting process, combined with reductions in batch processing time and material wastage, especially with expensive high performance alloys.

Rapid Prototyping

Supreme can offer a range of digital solutions to prototype and very low volume production parts without the use of traditional tooling. Additive technologies such as Fuse Deposition Modelling and 3D wax printing together with conventional CNC machining of foam and wax blocks can produce patterns which can be used in our standard casting process, producing items suitable for design validation without tooling investment.

Heat Treatment

General Heat Treatment

We provide a full range of general heat treating available; annealing, stress relieving, normalising, homogenisation, tempering, precipitation, etc.

Vacuum Furnace

Heat treating under a vacuum maintains the surface finish of components during treatment.
Vacuum heat treating is used for bright hardening and tempering, bright annealing, solution annealing of stainless steel, and vacuum brazing.

Induction hardening

Induction hardening is a process where the component is heated by electromagnetic induction. A high frequency current is passed through a coil that is in close proximity to the area to be heated. The heated area is then quickly quenched using water spray. The heating and quenching is very rapid and localised.

Carburising

A surface hardening treatment in which carbon is diffused into the surface of a low carbon/low alloy steel at high temperature (approx. (900ᵒC). After quenching the result is a component with high hardness on the surface, but with a softer, tough core.

Nitriding

Nitriding is a surface hardening treatment that introduces nitrogen into the surface of the steel at a relatively low temperature (approx. 520ᵒC). At this temperature the nitrogen reacts with alloying elements in the steel and forms a hard compound known as a ‘nitride’. Because of the low processing temperatures and the absence of quenching, nitriding is a very low distortion process in comparison to conventional heat treatment.

Carbonitriding

Similar to Carburising but as well as diffusing carbon into the steel and addition of nitrogen is made at the same time.
Surface Finishing and Coatings

We provide a wide range of surface finishing options. These include physical finishes such as:

  • Sand, shot and glass bead blasting 
  • Polishing – by hand and automated

Chemical finishes such as:

  • Painting
  • Electro-polishing
  • Electrolytic and electroless plating (eg Nickel or Cadmium)
  • Conversions coatings such as anodising, phophating and black oxide
  • Milspec coatings
Assembly

Supreme have expertise in providing fully built metal component assemblies. Working to customer specifications we regularly supply assemblies or sub-assemblies ready for integration into larger systems. The near net shape process economically justifies complicated and multifunctional parts to be specified. Typically system performance is improved by gains in Strength-to-weight and reduction in part number count over existing fabricated designs. Design for Manufacturability and Assembly (DFMA) techniques are highly compatible with the investment casting process and large labour and logistics savings with functional improvements are readily achieved.

Inspection & Testing

We provide a wide range of inspection and test services such as the following:

  • Metal chemical analysis: Chemical analysis of alloys using an ARL 3460 optical emission spectrometer running the latest OXSAS analytical software
  • Mechanical testing: A wide range of testing can be done including: tensile, impact, proof load and wear testing
  • Non-destructive testing (NDT): This includes Radiography, Ultrasonic, Liquid penetrant, magnetic particle and, magnetic permeability testing

Inspection and design verification reports - our CMM can produce automated reports on casting surfaces and compare dimensional deviations to the parts' CAD file. Very valuable for first off evaluation before and after machining.

CMM Capability:

  • Temperature stabilised metrology lab – full range of handheld measuring instruments.
  • Co-ordinate measuring machine: Sheffield Discovery 3 with PC-DMIS Cad control software.
  • CAD software: Solidworks 2012 Premium -including FEA of parts and assemblies.
  • High resolution optical 3D scanner: GOM ATOS 1+, scan error typically < 0.03mm.
ITAR Telarc9001 ABS DRS ​ ​ ECOAustmine
 
CONTACT US
Free Phone Australia:  1800 006 696    Free Phone New Zealand:  0800 5678 929    Email: enquiry@smcs.com