Processes & Technologies

Magellan’s investment in new technologies, state-of-the-art production equipment, and modern operating systems deliver distinct advantages over the competition.

Magellan’s facilities are AS9100 certified with all foundry processes in-house. Special processes are NADCAP certified.

3D Sand Printing


Applying 3D printing technology to the sand casting process allows Magellan to manufacture complex sand cores and molds directly from CAD data, eliminating the need for hard tooling in certain applications such as for prototypes. For production applications, low cost hybrid tool options are more cost effective. 3D sand printing technology yields highly accurate and repeatable results with the flexibility to easily accommodate customer design changes.

Simulated Metal Pouring & Solidification Modeling

Using the latest in metal simulation software, Magellan is able to accurately predict casting quality prior to investing significant time and resources into metal pouring trials. The result is a shortened overall lead time to develop a new program and a more robust metallurgical process is established for serial production.

Automated Pouring

Once metal simulations are optimized, controlled pouring of the molten metal is critical to ensuring the metallurgical integrity of each casting. Advanced automated pouring equipment at Magellan, tightly controls pouring process variables such that superior, part-to-part results are achieved.

Automated Finishing


Incorporating automated equipment such as CNC machining centres into the finishing process, improves overall dimensional control, part consistency, as well as it helps ensure zero process-generated defects.

Digital Radiography

Automated digital radiography provides for the rapid capture of high resolution radiographic images of castings eliminating conventional film processes.

Haley digital xray

3D Scanning

Digital scanning is employed at key stages of the casting operation to provide critical process control monitoring and to help ensure castings are fully compliant to drawing requirements.


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