The best manufacturing outcomes typically come from combining processes rather than choosing between them. While precision machining and casting each have distinct strengths, combining them unlocks new possibilities for manufacturers in terms of quality, efficiency and performance.
In this blog, we’ll cover how machining and casting complement each other, why hybrid manufacturing delivers the best results and how Topcraft uses both methods to meet demanding specifications.
The Power of Combining Casting and Machining
1. Casting for Complex Shapes, Machining for Precision
Casting excels at producing intricate geometries (hollow sections, internal cavities and organic forms) that would be costly or impossible to machine from solid stock. However, cast parts often require post-casting machining to achieve tight tolerances, smooth surfaces and functional features like threaded holes or sealing surfaces.
Example: An aerospace turbine blade may be cast to capture its complex airfoil shape then CNC-machined to provide precise mounting points and aerodynamic edges.
2. Overcoming Casting Limitations with Machining
While casting is efficient for large volumes, it can introduce minor imperfections like:
- Dimensional variations caused by cooling shrinkage.
- Surface roughness requires finishing.
- Internal porosity affecting structural integrity.
CNC machining addresses these issues by:
- Trimming extra material (removing gates and risers).
- Achieving micron-level accuracy on critical features.
- Improving surface finish for reduced friction or aesthetic appeal.
3. Hybrid Workflows for Cost and Time Savings
For medium to high production runs, casting near-net shapes and finishing with machining reduces:
- Material waste (vs. machining from solid billet).
- Machining time (less material removal needed).
- Tooling costs (compared to full CNC production).
Industry Applications: Where Casting + Machining Shine
1. Aerospace & Defense
- Engine housings are often cast for lightweight strength then machined to for precise bolt patterns and sealing surfaces.
- Turbine components benefit from casting’s heat resistance, with CNC-machined cooling channels for optimal performance.
2. Automotive
- Transmission cases are die-cast for high-volume production, then machined for gear alignment and bearing seats.
- Suspension parts (e.g., control arms) may be squeeze-cast for durability, with CNC-drilled mounting holes.
3. Medical & Industrial Equipment
- Pump housings are investment-cast for corrosion resistance, then machined to ensure leak-proof tolerances.
- Hydraulic valves combine cast bodies with precision-machined ports for fluid control.
Why Choose Topcraft for Hybrid Manufacturing?
At Topcraft Precision, we specialize in strategic manufacturing partnerships. Our approach includes:
- Networked Expertise: We collaborate with certified casting suppliers while handling precision machining in-house, using Solidworks simulation to verify designs before production begins.
- 4-Axis Machining Capabilities: Our CNC equipment delivers the accuracy needed to finish cast components, achieving tight tolerances on complex geometries.
- Material Flexibility: We work with aluminum, steel, brass and high-performance alloys from our supplier network, optimized for your application.
- Quality Assurance: ISO-certified inspections guarantee that cast-and-machined parts meet stringent tolerances.
Conclusion: Better Together
While standalone casting or machining each have merits, their combination delivers:
- Complexity + Precision: Cast intricate shapes, machine critical features.
- Efficiency + Accuracy: Reduce waste and machining time without sacrificing quality.
- Durability + Performance: Minimize porosity risks with post-cast CNC refinement.
Need a partner who can create successful value streams? Topcraft Precision utilizes a network of certified suppliers combined with its machining capabilities to achieve these objectives.
Contact us today to discuss hybrid manufacturing solutions for your next project!