Frequently asked questions

  • Is Fusium the right fit for my project?

    Fusium specializes in the production of custom cast metal components, ranging from prototypes to medium production runs.

    With expertise in iron, steel, aluminum, and magnesium alloys, Fusium works with customers across industries such as heavy equipment, mining, power generation, transportation, and industrial manufacturing.

    The company’s integrated capabilities, from design support and pattern making to casting and machining, make it an ideal partner for projects requiring technical expertise, flexibility, and high-quality castings.

  • What is the difference between sand casting and other manufacturing processes?

    Sand casting is a process where molten metal is poured into a mold made from sand. Once the metal solidifies, the mold is broken to reveal the final part.

    Compared to other manufacturing techniques, sand casting offers several advantages:

    • Ability to produce complex geometries and internal cavities
    • Lower tooling cost, especially for small or medium production runs
    • Capability to cast very large or heavy components
    • Compatibility with a wide range of ferrous and non-ferrous alloys

    This makes sand casting particularly suitable for custom parts, prototypes, and specialized industrial components.

  • Can you handle complex geometries and custom alloys?

    Yes. Fusium specializes in producing complex, custom castings, including thin-walled components and parts with challenging geometries.

    The company works with multiple alloy families, including:

    • Gray iron
    • Ductile iron
    • Compacted graphite iron
    • Carbon and stainless steel
    • Aluminum alloys
    • Magnesium alloys

  • Why choose sand casting over welded metal?

    While welded assemblies can work for certain applications, sand casting often offers significant advantages:

    • A single part eliminates weld joints and potential weak points
    • Improved structural integrity and durability
    • More design freedom, including complex shapes and internal features
    • Reduced assembly time and costs

    For many industrial components, casting a part as one piece can improve performance and reliability compared to welded fabrications.

  • What is your typical lead time for prototypes vs. production orders?

    Lead times vary depending on the specifics of each project. Factors such as the need for new tooling, part complexity, required testing, and order quantities all influence the timeline.

    Production orders may require additional time depending on volume and process requirements. We work closely with each client to establish realistic and reliable delivery schedules.

  • Is there a minimum or maximum order quantity?

    Fusium specializes in small to medium production runs, including prototypes and limited series.

    Depending on the alloy and project requirements, production volumes can scale up from 1 to approximately 1,000 parts per year. We evaluate each project individually to ensure the most efficient and cost-effective approach.

  • What are your minimum and maximum casting size and weight capacities?

    Casting capacity depends on the material used and the yield of metal poured to casting weight. Examples include the following poured weights:

    • Gray or ductile iron: approximately 200 lbs to 16,500 lbs per part
    • Steel and stainless steel: up to approximately 4,000 lbs
    • Aluminum: up to approximately 500 lbs
    • Magnesium: up to approximately 300 lbs

  • What is the yield of metal poured to casting weight?

    It is the percentage of the final casting weight compared to the required poured weight of liquid metal in the mold. Poured weight includes piping and feeding aids.

    This percentage can range from 30% to 90%, depending on the alloy, application, and quality requirements.

  • Do you provide design assistance or only manufacturing?

    Fusium can support projects from the early design stages through production.

    The team can work with clients to optimize part design for casting, ensuring the final component meets required performance, manufacturability, and cost objectives.

  • Do you provide machining or finishing services in-house?

    Yes. Fusium offers turnkey solutions, meaning parts can be delivered fully finished if required, including machining and other finishing operations.

  • Do you ship internationally?

    Yes. Fusium frequently works with customers across North America and internationally, supplying cast components for a wide range of industries.

  • What information do you need to provide a quote?

    To prepare an accurate quotation, it is helpful to provide:

    1. Alloy
    2. Quantities
    3. Approximate weight or dimensions
    4. 2D drawing, for machining if required
    5. 3D drawing or STEP file
    6. Final use of the product, which always helps us during the design process
    7. Whether you will provide a pattern/model or need us to make it
    8. Any specific quality tests required

    Any other information you believe is relevant is also helpful.

  • Do I absolutely need a drawing to quote my request?

    A drawing or 3D CAD model is strongly recommended to provide the most accurate quote.

    However, Fusium may still be able to evaluate certain projects based on basic dimensions, pictures, or descriptions.

  • Can Fusium produce a part by scanning an old one?

    To manufacture a part, a technical drawing or 3D model is required.

    If these are not available, Fusium can support your project through trusted partners who offer 3D scanning and reverse engineering services. This allows us to recreate a detailed drawing from an existing part and proceed with production.

  • What quality control measures do you have in place?

    Each Fusium facility is supported by a dedicated quality control department that oversees inspections throughout the production process.

    This ensures that all parts meet applicable standards, specifications, and customer requirements before delivery. Our quality processes are designed to maintain consistency, reliability, and high performance across every order.

  • Do you provide material certifications and traceability?

    Yes. Fusium can provide material certifications and documentation in accordance with industry requirements and applicable standards.

  • Can you perform non-destructive testing, such as X-ray or ultrasonic testing?

    Yes. Fusium works with a network of trusted, qualified partners to provide non-destructive testing (NDT) services such as radiographic (X-ray) and ultrasonic inspections.

    These services can be integrated into your project as needed to ensure the integrity and performance of your cast components.

  • Do you provide dimensional inspection reports?

    Yes. Dimensional inspection and verification can be provided when required to ensure parts meet specified tolerances and technical requirements.

  • What is Fusium’s quality policy?

    Fusium is committed to delivering high-quality castings, reliable lead times, and strong customer collaboration throughout the entire project lifecycle.

    Each project is approached as a partnership, ensuring the final component meets both technical and operational requirements.

  • How is pricing determined?

    Pricing depends on several factors, including:

    • Material type
    • Part size and weight
    • Design complexity
    • Tooling requirements
    • Quantity ordered
    • Manual labour
    • Machining and finishing needs

    A detailed quotation is provided after reviewing the project specifications.