Engineer Blog & Technical Knowledge Hub

Tooling is the foundational stage of investment casting. CNC machined from aerospace-grade aluminum or tool steel, the mold creates precise disposable wax replicas with exact shrinkage compensation.

The ceramic shell molds molten metal at extreme temperatures. PT ZAP employs a 6-to-8 layer automated robotic dipping process using premium colloidal silica slurries and graded fused silica refractory sands.

While sand casting is suitable for large, simple raw castings, investment casting offers near-net shape accuracy, superior surface finish (Ra 3.2 µm vs Ra 12.5 µm), and thin walls down to 1.5 mm, saving up to 40% in total machining costs.

ElectroPolishing is an electrochemical process that removes micro-burrs and microscopic high points from stainless steel castings (CF8, CF8M, Duplex, Titanium), enriching the surface with chromium oxide (Cr2O3) to achieve Ra < 0.4 µm.

Casting without high-precision machining is only half the solution. PT ZAP operates an in-house fleet of 30 CNC machine units, including 5-Axis DMG Mori DMU 50 and Citizen Swiss lathes, ensuring tight ±0.005 mm tolerances.

PT ZAP guarantees 100% dimensional compliance using high-precision CNC Mitutoyo 3D Coordinate Measuring Machines (CMM) and ZEISS optical scanning systems for complete GD&T verification and EN 10204 3.1 inspection certification.

Through its dedicated ZENMED+ division, PT ZAP produces ISO 13485 certified orthopedic trauma implants, bone screws, and spine fixation hardware, combining vacuum metallurgy, 5-axis Swiss machining, and cleanroom packaging.

Critical industrial applications in valves, rail, and energy require rigorous NDT. PT ZAP performs 100% in-house Liquid Penetrant Testing (LPT), Ultrasonic Testing (UT), and Magnetic Particle Testing (MT) in accordance with ASTM and ISO standards.