Our Process
Our Process: From Concept to Casting
At One Off Castings, we specialize in transforming complex, one-time designs into reality. Our integrated approach combines advanced robotics, precision tooling, and decades of foundry expertise to deliver high-quality castings efficiently and reliably.
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Phase 1
Project Setup
Reverse Engineering
We 3D scan your casting to precisely recreate the model for legacy or undocumented parts.
Submit Your CAD or Concept
Submit your CAD design or concept for our team to review and assess.
Intro Call & Quote
We review your goals, provide a tailored quote, and answer any technical or timeline questions.
Submit Purchase Order
Once approved, your project moves into the production phase.
Phase 2
Engineering & Production
Engineering Review & Simulation
Our team validates and optimizes your part using CAD and flow/solidification modeling.
Mold & Core Design
We engineer and simulate the mold for performance, cost-efficiency, and reliability.
Robotic 3D Printing (RoboCast)
Our ABB robots 3D print your core or mold directly from the model — no patterns needed.
Metal Pouring
We pour your chosen alloy under tightly controlled conditions, ensuring material integrity and precision.
Phase 3
Quality & Delivery
Cleaning & Laser Scanning
Parts are cleaned and inspected via FARO scanners and/or CMM tools. Inspection reports available upon request.
Quality Control
If required, mechanical testing, dimensional reporting, or non-destructive testing (MPI/LPI) is completed.
Shipping & Logistics
We handle packaging and delivery with full traceability and documentation.