We shape Aluminium with

Gravity!

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Aluminium...a building block of the circular economy!

Aluminium is playing more and more a relevant role in decarbonization and can be a building block of the circular economy thanks to its unique qualities - such as its infinite recyclability without degradation of quality (it’s estimated that 70% of ever produced aluminium is still being in use). Adding to that its:

  • High electrical and thermal conductivity
  • Resistance to corrosion
  • Softness and lightness
  • Combined with other metals for increased hardness, preserves its low density.

Makes aluminum a solid bet for your products and projects.

To be part of this change, FABCAST was created and is present to help you develop your projects where:

  • High customization
  • Fast development and prototyping
  • Small (until 1.000 units/year) to medium size (50.000 units/year) lots are involved at an affordable cost.

Consult us!

Overview

FABCAST was created and is present to help you develop your projects when is required:


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Customization

high level of customization


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Development

fast development and prototyping


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Capacity

small (until 1.000 units/year) to medium size (30.000 units/year) lots are involved at an affordable cost


About us

Based in a tradition of nearly a century in gravity casting, FABCAST is a project born in 2017, to satisfy the global demand for aluminum gravity casted produced parts.The industrial building covers a total area of 7 000 m2 in a land property of 26 000 m2, that leaves expansion opportunities for the future. FABCAST manufactures through foundry gravity, No-bake Sand Casting and Gravity Die-Casting processes, parts of high technical complexity resulting of a vertically integrated process: Project-Mold shop-Casting-Finishing-Heat Treatment-Machining.

FABCAST has a continuous improvement strategy, based in three vectors: Productive Innovation, Product Quality and Quick and Reliable Service. FABCAST invested nearly 5 million euros in the period 2017-2019 in technological innovation across Engineering, Production, Quality control and Integrated Management System (ERP). FABCAST wants to be known in our industry as a reliable, high quality, with moral integrity and honest competitive practices, with respect for social and environmental standards.

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Processes

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Pattern shop

To assure delivery dates and quality of nobake sand casted parts, FABCAST has its own pattern shop, integrating skilled and experience workers and the complete mould construction and production center with CNC machinery – 5 Axis and 3D Printer.

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Melting

In the melting area, equipped with 6 furnaces (300 to 600Kg), we use only 1st fusion alloys:

  • AlCu4MgTi
  • AlSi7Mg0.3
  • AlSi7Mg0.6
  • AlSi12
  • AlSi10Mg
  • AlSi12CuNiMg
  • Special Alloys
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Nobake sand casting

Nobake sand gravity casting is performed in our modern semi-automatic line and, for big casting, on the floor. We can produce castings with a 2000 x 1500 mm maximum and 700 kg in weight.
Our warehouse of patterns, produced internally or transferred by clients, is continuously growing and has already two hundred patterns adequately preserved and insured.

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Die casting

With investments in progress to increase our capacity in volume, lot size and parts dimension, our die casting process involves 3 furnaces around 300 Kg each one and 9 die cast machines (horizontal, vertical, tilting). We are able to die cast parts up to 1000 x 800 mm and 20-30 Kg in weight

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Core shop

To assure the needs of nobake sand casting and gravity die casting, from simple to complex, from small to big , FABCAST has in its core shop area the means to produce cores using two different technologies: cold box and hot box.

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Fettling

Combining robotized fettling with highly skilled workers, here is where casting are shot-blasted, feed and sprues separated and where grinding and polishing occurs. This a very tough and skilled workmanship, which is decisive for reaching a quality part. These activities are performed with attention to safety and healthiness of workers.

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CNC Machining

FABCAST is able to perform CNC machining for most of the common range of your parts. When big dimensions are involved, FABCAST uses it’s network of subcontractors, always assuring with its own means quality required by clients With 3 CNC centers miling machines, 2 CNC lathes and others conventional machines with the following capacities:

  • Horizontal CNC Center Machine 3 Axis 1600 x 1000 x 790 mm
  • Vertical CNC Center Machine 3+1 Axis 1016 x 508 x 635 mm
  • Vertical machining center 5 Axis 1016 x 635 x 635 mm
  • Vertical machining center 5 Axis 762 x 508 x 508 mm
  • Horizontal CNC Lathe Ø430 x 860 mm
  • Vertical CNC Lathe Ø830 x 750 mm
  • Diverse Conventional Lathes

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Heat treatment

FABCAST invested in a heat treatment facility able to achieve the highest standards in aluminium heat treatment (Class 2). With the heat treatment of our castings we improve the casting uniformity, strength, abrasion and corrosion resistance of your part. FABCAST parent company has in the group a company specialist in heat-treatment of metals that serves the automotive industry for many years. FABCAST can also perform heat treatment for your structural parts on a subcontract basis, preserving the maximum confidentiality.

QUALITY

A Pillar of our culture

FABCAST has on its top management a person which devoted most of his career to quality management systems conception and also audit.
So, it’s on the core of our culture, to take the most attention to the quality management system, including product and process inspection.
FABCAST invested from the start in the state-of-the-art means.
FABCAST has the complete means for chemical composition, thermal analyses, density, material structure, mechanical properties and, very important, also to detect internal pathologies in the parts. Our metallurgy lab is composed by experienced metallurgical engineers and the following equipment’s:

  • Spectrometer
  • Thermal analysis
  • Density
  • Optical microscopy with images analysis
  • Radioscopy
  • Mechanical test machine
  • Hardness
  • CMM machine
  • Scanner arm
  • Roughness equipment
  • Pressure Test
  • Leak Test
  • Sand laboratory

Services

We have far more to offer than Aluminium casted parts.
CONSULT US FOR:

TEAM

The top management of FABCAST is composed by the decades experience of two metallurgical engineers, with solid background in the casting for automotive industry and other industries, and an Economist, all with solid experience as Entrepreneur and Director level. The trio cover main functional areas in the organization: Commercial, Engineering, Production, Maintenance, Quality, Environment & Safety and Financial.

At middle management level, FABCAST has 6 engineers (metallurgical and mechanical) assuring CAD-CAM, metallurgical control, production (from casting to machining) and quality control.

Production subteams are supervised by experienced workers coming out from the casting tradition that preceded the FABCAST project.

On Administrative area covering the supply-chain administrative (purchasing, ERP management, stocks, invoicing) tasks we have management graduated persons. Other administrative tasks (Human Resources, Accounting and Financial) are assured at corporate level. The number of elements in the team has been increasing with focus on middle management areas and production teams, because FABCAST uses ERP and CRM technologies, making FABCAST a lean structure company.


Contact us

Parque Ind. Sobreposta, Lugar da Alagoa
Este (São Pedro e S. Mamede), 4715-533 Braga
Portugal

GPS: 41.560578, -8.349891

(+351) 253 777 009

info@fab.pt