Castings that hold pressure, tolerance and promise.
We pour, cast, trim and machine aluminium components on fully automatic TOYO presses — with melt chemistry, hydrogen content and porosity verified in-house before a single shot is fired.
A young plant built around old-fashioned metallurgical discipline.
Castman Technologies is an aluminium high pressure die casting manufacturer in Coimbatore, Tamil Nadu. We commissioned our first fully automatic TOYO press in 2023 and have been adding capability every year since — a second 350 T machine in 2025, shot blasting and turning in mid 2025, trimming in 2026.
What sets the plant apart is not its age. It is that every melt is spectro-tested, degassed under interlocked parameters, and pressure-tested for hydrogen before casting — the kind of front-end control that usually shows up only in far larger foundries.
Six industries, one process discipline
From 0.1 kg electrical housings to 1.4 kg street light bodies — the sectors change, the melt control does not.
Automotive
2W & 4W engine, brake, gearshift and wiper components
View partsHydraulics & Pneumatics
Swivel flanges, cylinder end covers, valve bodies
View partsElectrical & Lighting
LED holders, street light bodies, load-bearing cable hangers
View partsOil & Gas Dispensing
Fuel gun couplings, pulsers, junction boxes, filter bodies
View partsDomestic Appliances
Mixer housings and wet grinder motor covers
View partsPrecision & Thin Wall
1.5 mm walls, ±0.1 mm tolerance, banking & instrumentation
View partsWe also hold experience in textile machinery parts, off-road vehicle components, and medical & aerospace castings.
Melt quality is decided before the shot
Most casting defects are metallurgical, not mechanical. So our process front-loads verification — chemistry, hydrogen, porosity — then locks the parameters with poka-yoke interlocks so an operator cannot deviate.
Alloy in, identity kept
Ingots are stored by colour code and heat number, so every casting traces back to a known batch. We work Al‑Si, Al‑Cu and Al‑Mg families — including hyper-eutectic 16% Si for wear resistance and no-silicon AlMg2 where load-bearing strength matters.
Chemistry confirmed on an OES spectrometer
A Metal Power MOSS optical emission spectrometer reads 15+ elements across multiple bases, in-house, on every melt. Nothing is cast on assumption.
Degassed under interlocked parameters
Rotary degassing with flux injection, error-proofed on gas pressure, gas flow and rotor speed. If a parameter drifts outside window, the cycle interlocks. Every cycle is printed and recorded.
Hydrogen verified by reduced pressure test
A vacuum sample is drawn to 0–700 mmHg and sectioned. Porosity and blowholes are assessed before the melt is released, and a QA-authorised person signs the melting quality log.
Cast on fully automatic TOYO presses
250 T and 350 T BD‑V7EX machines with multi-step injection, capable of 100G acceleration. The 350 T adds squeeze pin and jet cooling for section-thickness control.
Finished, measured, dispatched
Trimming, shot blasting to a bright finish, band saw cutting, belt sanding and CNC turning in-house. Surface treatment — powder coat, E-coat, anodising, chromating — through qualified partners.
What we are actually good at
Complex, intricate geometry
Thin walls down to 1.5 mm, ±0.1 mm tolerances, and warpage held under 0.2 mm across a 300 mm span — proven on production parts, not just samples.
Quick response
A flat, three-person leadership structure means enquiries, revisions and escalations reach a decision-maker the same day.
Leakproof castings
Wet and dry leak testing for pressure-critical parts — pneumatic cylinder covers, brake valve bodies, fuel dispensing components.
High and low volume
We quote a 250-piece first batch with the same seriousness as a running programme, so new products can be proven without committing to volume.
3D & 2D — proto to finished part
Filling, shrinkage, velocity, air entrapment and thermal distribution simulated before tooling is cut. You see the risk before you pay for the die.
Competitive on tool and part
We price the die and the piece together, so the total programme cost is visible from the first quotation rather than recovered later.
We simulate the shot before we cut the die
For new development work we run a full flow simulation — filling pattern, shrinkage, gate velocity, air entrapment and temperature distribution — and share the study with you.
- Gate and runner design validated against fill time and velocity limits
- Shrinkage porosity predicted and addressed with overflow or squeeze pin placement
- Air entrapment zones identified so venting is designed in, not retrofitted
- Thermal distribution checked to size cooling lines correctly the first time
Our castings reach programmes at
Castman supplies as a Tier 2 and Tier 3 partner. Logos indicate end-programmes our castings reach through our direct customers. See our direct customers.
Customers audit us on the floor
Indian and international teams walk our line, review our melt logs and sign off our process before a programme starts. We would rather be inspected than described.
Send us a drawing. We will send back a real answer.
Part print, 3D model or even a sample in hand — we will tell you the alloy, the likely process route, the tooling approach and an honest lead time.