Where Conventional
Casting Reaches
Its Limit, We Don't.
Complex Geometries
Residue-Free Removal
One-Piece Casting
Available in India
GDC · LPDC · HPDC
Design freedom beyond conventional mould limits
Core In.
Water Out.
Geometry Done.
The Capability
Dissolving-Core
Aluminium Casting
Creative Alucast has developed a specialised aluminium casting process using water-soluble expendable cores — engineered for components that demand internal cavities, undercut geometries, and hollow structures that no conventional mould, slider system, or thermal de-coring method can produce.
The expendable core is placed inside the die before casting and cleanly dissolved in water after — leaving behind a flawless internal geometry with zero residue and no damage to the part.
When thermal de-coring fails
Our water-soluble core removes cleanly every time — no heat stress, no vibration, no breakage risk to the finished casting
When sliders cannot reach
Internal channels, blind passages, and deep undercuts — geometries that no die and slider system can physically produce — castable in a single shot.
Near-net-shape, first time
No secondary machining or post-assembly required for hollow features — the internal geometry is cast in with the part, not manufactured into it afterwards.
Clean and environmentally sound
No resins, no smoke, no toxic binders. The core dissolves in water and is fully recyclable — a process that is clean at every stage.
How It Works
Five Steps to an
Impossible Geometry
From design to finished casting — the dissolving-core process
integrates into
existing die casting workflows with no exotic equipment required on the
customer side.
1
Core Design & Manufacture
The expendable core is engineered to match the desired internal geometry — designed to withstand casting conditions and dissolve cleanly in water.
2
Core Placed in Die
Before the casting shot, the core is positioned precisely inside the die cavity — locating pins ensure dimensional accuracy of the final internal feature.
3
Aluminium Cast Around Core
Molten aluminium fills the die — flowing around the core at casting pressure. The core maintains its shape throughout the solidification cycle.
4
Part Ejected with Core Intact
The casting is ejected from the die with the core still inside — fully encased within the solidified aluminium, exactly where the internal cavity will be.
5
Core Dissolved in Water
The core is dissolved using water — completely, residue-free, with zero mechanical stress on the casting. The internal cavity is revealed in its final form.
Why This Capability
Capabilities That Redefine
What's Castable
Six properties that separate dissolving-core casting from every conventional
alternative — and make it the right answer for geometries that previously had no
good answer.
Extreme Geometry Freedom
Blind undercuts, internal channels, curved passages, hollow structures — geometries that dies, sliders, and sand cores physically cannot produce are castable in a single shot.
Residue-Free Removal
The core dissolves completely in water — no sand fragments, no mechanical stress on the casting, no residue inside the cavity. The internal surface is clean and uncompromised.
Lightweighting
Hollow, one-piece aluminium castings deliver significant weight reduction without sacrificing structural integrity — critical for automotive, EV, and aerospace applications.
Fewer Operations
Internal features are formed at the casting stage — eliminating secondary drilling, welding, or multi-piece assembly for hollow sections. One part. One process.
Clean Process
No resin, no smoke, no toxic emissions. Natural raw materials, water-based removal, recyclable by design. A manufacturing process that is clean at every stage.
Geometry Confidentiality
Internal features produced this way cannot be reverse-engineered from external inspection of the part. Your internal geometry — your design — stays yours.
Applications
Built for Demanding
Industries
If your component has internal passages, undercuts, or hollow structures that
your current
supplier cannot achieve — this is the capability you have been
looking for.
Automotive
Oil & Coolant Channels, EGR Mixers, Valve Bodies
- Internal cooling or oil channels in a single casting
- EGR mixer and valve bodies with blind internal geometry
- Weight-optimised structural brackets with hollow sections
EV & E-Mobility
Motor Housings, Battery Enclosures, Thermal Plates
- Integrated cooling passages in motor housings
- Battery enclosures with internal thermal management channels
- Consolidating welded sub-assemblies into a single casting
Pump & Industrial
Pump Bodies, Manifolds, Hydraulic Components
- Pump bodies with crossing internal flow passages
- Hydraulic manifolds with blind and intersecting bores
- Valve bodies requiring undercut internal seating geometry
Fire & Safety Equipment
Valve Bodies, Suppression System Components
- Suppression system valve bodies with internal flow geometry
- Pressure-rated components with complex internal passages
- Single-piece housings replacing multi-component assemblies
Our Commitment
Solving the Problems Others Pass On.
We have invested in developing casting capabilities
that go beyond the conventional — so that when a customer brings us a difficult geometry, our answer is a
solution, not a limitation. This is how we engineer
smarter, together.
Dissolving-Core vs Conventional Alternatives
| METHOD | ||||
|---|---|---|---|---|
| DISSOLVING-CORE | ✓ | ✓ | ✓ | ✓ |
| SLIDER / DIE CORE | Limited | ✓ | ✓ | ✓ |
| SAND CORE (GDC) | ✓ | Residue risk | ✓ | ✓ |
| THERMAL DE-CORING | Limited | Breakage risk |
Heat stress | ✓ |
| MULTI-PART ASSEMBLY |
✓ | ✓ | ✓ | No — joined |
Design freedom beyond conventional mould limits
Tell Us What You
Couldn't Cast Before.
look at it.
- No-commitment design review — we'll tell you if we can solve it
- Compatible with GDC, LPDC, and HPDC processes
- Available in India — Rajkot, Gujarat
- Response within 1 business day
Engineering Contact
sales@creativealucast.com
Call Us
+91 98989 34099
Location
Ribda, Rajkot, Gujarat 360311
FAQ
Common Questions
evaluating dissolving-core casting for their
application.