Way of working

At Fonderie Laval, we take on the entire production process in house. From the initial concept to the final product, every step is handled within our facilities or at one of our partners within Gietburg Group. Our advanced shell moulding technology and state-of-the-art equipment ensure that we deliver high-quality cast components with precision and efficiency. This integrated approach allows us to maintain strict quality control and meet the specific needs for a large variety of sectors.

Our process consists of the following steps:

1. Development and sourcing

We start with an initial consultation to understand the client's specific needs and requirements. Our team of resident engineers collaborates closely with clients to develop detailed designs using advanced CAD software and casting simulation programs. During this phase, we also source high-quality materials, including ductile iron, steel, and SiMo, and create prototypes to ensure the best resources and optimal design for the process.

2. Shell moulding

With our shell moulding technology, we create precise moulds that offer superior surface smoothness and accuracy. This process is ideal for complex, thin-walled components such as gearbox parts, propellers, and exhaust manifolds. Our shell moulding capabilities allow us to achieve wall thicknesses as fine as 2 mm, compared to the 8-9 mm possible with sand moulding.

3. Core making

We use electric ovens to melt ductile iron, steel, and SiMo in various grades. This process ensures a clean process, with lower CO2 emissions compared to traditional coke ovens. The molten metal is then poured into the shell moulds, where it cools and solidifies to form robust, high-precision components. Our in-house core making involves using hot box technology to create fine-grain, precise cores, which are essential for achieving detailed castings with specific hollows and indentations. This step is crucial for components that require high accuracy and cannot be machined post-casting.

4. Machining and finishing

After casting, the components undergo in-house machining processes such as turning and milling, ensuring that each part is fully finished and meets the highest standards for immediate use. For more complex machining tasks, these are managed by one of the other divisions within the Gietburg Group. This approach allows us to handle all processes internally while maintaining complete control over quality and efficiency.

5. Quality control and delivery

We adhere to strict quality control measures throughout the shell mould casting process, in line with our IATF 16949 certification. This certification ensures that our processes meet the highest standards of quality management systems, specifically for the automotive sector. Our skilled team ensures that every casting meets these rigorous standards of excellence. With our state-of-the-art facilities, we prioritise precision, dimensional accuracy, and superior surface finish to deliver castings that consistently exceed our customers' expectations.

Afterwards, we conduct thorough in-house testing processes, including assembly, painting, and leak testing, to ensure all parts meet the highest standards before delivery. Then, components are delivered at our customers’ facilities, ready to be integrated into their production process.