Massive, Precision-Engineered Castings for Demanding Industries
At Align Manufacturing, we specialize in producing large-scale sand castings that most global foundries simply can’t handle. Our advanced facilities in India manufacture castings that weigh from hundreds of kilograms to over 15 metric tons, built to exacting standards for high-stress industrial applications.
Because of their massive size and critical performance requirements, these castings demand a different level of craftsmanship and control. Every part is hand-formed, slow-cooled, and meticulously poured to guarantee structural integrity and dimensional accuracy.
What Makes Our Large-Scale Sand Casting Different?
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Truly Massive Sizes
Our castings are among the largest produced in the world, ranging up to:-
Gray Iron: 500 kg to 15 tons
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S.G. (Ductile) Iron: 500 kg to 10 tons
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Carbon & Alloy Steel: 100 kg to 4 tons
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Specialized Nighttime Pouring
Due to the volume of molten metal involved, each casting is poured individually at night to ensure temperature stability. Only one part per night can be produced, and depending on size, it may take up to two full weeks to cool before handling. -
Handmade Patterns and Molds
Every casting starts with manually crafted patterns.
The bottom mold half is filled first, then the top half is placed, and specialized sand mixtures are used to create the final cavity. When molten metal is poured, it melts the foam pattern inside, filling the shape with extreme precision. -
Material Expertise
We cast a variety of heavy industrial materials:-
Gray Iron (for excellent machinability and vibration damping)
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S.G. Iron (for high strength and fatigue resistance)
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Steel (for maximum toughness and critical applications)
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Industries and Applications We Serve
Our large-scale sand castings are engineered for industries where strength, scale, and durability are non-negotiable:
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Press Tool Dies Manufacturing
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CNC Machine Manufacturers (Horizontal Machining Centers / Vertical Machining Centers)
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Die Casting Equipment Builders (Gravity Die and Pressure Die Casting Machines)
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Pump and Valve Sector (Large valve bodies, pump casings)
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High-Pressure Die Casting Machine Manufacturers
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Railway Parts and Infrastructure (Brake systems, housings, riser plates)
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Gear Housing Manufacturers (for large industrial gearboxes)
Why Choose Align MFG
for Your Large-Scale Casting Needs?
India-Based Specialized Facilities
Our large castings are exclusively manufactured at high-capacity foundries in India, selected for their ability to handle extreme weights and precision tolerances.
Unmatched Size Capability
Few facilities globally can pour and process castings of this size, Align MFG partners with only the best.
Controlled Cooling for Integrity
Slow cooling over days or even weeks ensures minimal internal stresses and superior metallurgical properties.
Full Process Transparency
From handmade patterns to final machining allowances, we deliver detailed inspection reports and metallurgical testing as needed.
Typical Parts We Produce
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Large Valve Bodies
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Gear Housings
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Pump Casings
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Riser Plates
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Railway Structural Components
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High-Pressure Machine Frames and Dies
Ready to start your Heavy Sand Casting project? Contact us to submit your specifications, and our team will be ready to assist you every step of the way.
For further inquiries or to start a conversation with us, reach out through our RFQ form.