Melpo manages industrial parts production from design to foundry casting processend-to-end, keeping quality and specifications on track across every supply step.
Contact us >
What is a foundry casting process?
A foundry casting process is the traditional, and still highly advanced, way to transform raw metal into functional components for industry. It’s an intricate process that begins by melting selected materials into a controlled liquid state, then moulding them into parts designed to meet specific functional and performance requirements. Used for centuries and continuously refined, metal casting remains essential across all industries because it enables the production of durable components from a wide range of alloys, including aluminum, brass, iron, steel, and bronze, each with properties that influence strength, corrosion resistance, machinability, and final performance.
Since quality depends on precision and know-how at every stage, the casting foundry process requires experienced coordination, clear specifications, and rigorous controls to achieve reliable, repeatable results. This is where Melposupports European manufacturers: as a one-stop partner for casting, we manage qualified sourcing, supplier coordination, and inspection-driven quality assurance, helping you reduce risks and obtain cast parts that match your application needs and standards.
Key steps in the casting process
A typical casting process follows a structured workflow designed to control geometry, metallurgy, and repeatability, from the first design inputs to final inspection and delivery. Below are the main phases of the casting foundry process:
- Pattern & mould design, including gating and risers to manage metal flow and compensate for shrinkage
- Mould preparation, using sand systems or alternative tooling based on alloy, finish, and production needs
- Melting & alloy control, with strict management of temperature, chemistry, and cleanliness
- Pouring and controlled solidification, to limit defects and ensure consistent results
- Shakeout and removal operations, then cutting sprues and gates
- Cleaning & finishing, such as deburring and surface treatments when required
- Heat treatment and/or machining, to meet tolerances and functional surfaces for assembly readiness
- Quality checks and documentation, including certificates, dimensional inspections, and NDT when needed, followed by packaging and delivery
Melpo supports European manufacturers by coordinating these stages between suppliers, ensuring full traceability and quality control in accordance with ISO 900, customising inspections, documentation and NDT options according to the criticality of each component, in order to support a controlled path from prototype to series production. Learn more about our approach on our website and contact our team for a technical review of your component!
FAQ – Foundry casting process
What is the process of casting in foundry?
In a foundry, the casting process typically moves from making the mould to closing/clamping it, pouring molten metal through the gating system, cooling/solidification, removing the casting, and trimming sprues/gates, followed by finishing when needed. In Melpo projects, these steps are mapped and controlled across qualified suppliers with the right inspection plan and documentation to keep quality consistent from first samples to series deliveries.
What is the difference between foundry and casting?
A foundry is the facility where metal is melted and prepared, while casting is the manufacturing method of shaping molten metal inside a mould—the finished parts are “castings.” In practice, Melpo supports manufacturers by coordinating the foundry process end-to-end (supplier qualification, technical alignment, inspections), without being a direct foundry.
What are the 4 casting processes?
Four commonly referenced foundry processes include sand casting, investment casting, permanent mould casting, and die casting, often grouped by whether the mould is expendable or reusable. Melpo supports multiple routes depending on part geometry, alloy, and volumes, helping you select the most suitable approach.
Which is the most common foundry casting process?
Sand casting is widely described as the most common foundry casting process, thanks to its versatility across many alloys and part sizes. Melpo frequently manages sand-based projects (e.g., green sand, resin sand) with ISO 9001-driven quality assessment and NDT options when required.
Searching for a partner to manage your foundry casting process across Europe?
From supplier selection to documentation and quality checks, Melpo keeps your casting projects controlled and traceable, without the complexity of managing multiple vendors.
Learn more >
Would you like to receive more information or discuss your project with our team?
Fill out the form and one of Melpo’s specialists will get back to you asap.
