The USA-based customer approached with a requirement for a durable, corrosion-resistant switch cover for BBQ grills. The target was to ensure the product could withstand outdoor conditions, high temperatures, and prolonged exposure to grease, smoke, and moisture, while also maintaining an aesthetic appearance consistent with premium outdoor cooking equipment.
Custom investment cast stainless steel grill switch cover is a premium solution for high-quality BBQ grills and outdoor appliances. Designed for durability and precision, investment casting enables complex shapes and fine details, making it an ideal process for creating tailored switch covers.
Material: Brushed stainless steel (grade 304 or 316 for added corrosion resistance).
Aesthetic: Modern and sleek finish to complement high-end BBQ grills.
Durability: Resistant to corrosion, high temperatures, and wear from frequent usage.
Specific dimensions to fit their grill models.
Engraved logo and switch markings for branding.
Available Customization Options:
● Shape and Dimensions:
○ Precision casting for complex designs, including recessed or embossed features.
○ Custom hole placements for switches, buttons, or LEDs.
● Branding and Markings:
○ Laser-engraved logos or symbols for brand identity.
○ Raised lettering or patterns directly cast into the product.
● Surface Treatments:
○ Brushed or polished surfaces for a premium appearance.
○ Electropolishing for enhanced corrosion resistance and hygiene.
Must meet USA safety standards for outdoor appliances.
Grade 304 Stainless Steel was initially selected for its cost-effectiveness and excellent corrosion resistance.
After consultation, Grade 316 Stainless Steel was chosen for additional resistance to salt and marine environments, ensuring better performance in coastal regions.
The brushed surface is achieved through precision mechanical brushing to provide a sleek, non-reflective appearance while masking fingerprints and minor scratches.
Laser engraving for the customer’s logo and switch markings, ensuring durability without compromising the finish.
A prototype was produced and shared with the customer for review.
Adjustments were made to hole placement and dimensions based on the customer’s feedback.
A wax model of the switch cover is created using precise tooling.
The wax model is dipped into ceramic slurry and coated to form a hard shell.
Molten stainless steel is poured into the shell, replacing the wax.
After cooling, the shell is removed, and the part is cleaned, machined, and polished.
The customer praised the product's superior quality, finish, and corrosion resistance.
They highlighted the precise engraving and the durability of the switch cover.
Production batch: 100-250- 500+ pieces. Please provide a quotation for all the parts you can produce.
We can provide you with a quote for both investment casting and die casting including tooling and production.
1. Design Flexibility
Intricate Designs: Investment casting can produce highly detailed and complex geometries, including thin walls, embossed features, and recessed areas.
Customization: Allows for precise customization of shapes, dimensions, and features like holes, logos, and text.
No Machining Required: Reduces the need for secondary machining by casting the part close to its final shape.
2. Material Versatility
Wide Range of Stainless Steel Grades: Supports 304, 316, and other grades for specific corrosion, strength, or aesthetic needs.
Corrosion Resistance: Essential for outdoor BBQ grills exposed to moisture, grease, and varying weather conditions.
3. Superior Surface Finish
Smooth Finish: Produces a clean surface straight out of the mold, minimizing post-processing.
Optional Polishing or Brushing: Easily applies finishes like brushed, polished, or matte for aesthetic and functional purposes.
4. Tight Tolerances
Achieves tight dimensional tolerances, ensuring components fit perfectly into grill assemblies.
Reduces rework or adjustments during assembly.
5. Strength and Durability
Produces parts with excellent mechanical properties.
Suitable for demanding environments like high heat and exposure to chemicals or salt air.
6. Cost Efficiency
Material Savings: Minimal waste as excess material can be melted and reused.
Economical for Complex Parts: Eliminates the need for multiple parts by casting a single, integrated component.
Tooling Longevity: Wax molds are durable and reusable for medium to large production runs.
7. Scalability
Prototype to Mass Production: Supports small-batch production for prototyping and scales up efficiently for large orders.
Consistency: Ensures identical parts across multiple production runs.
8. Enhanced Branding Opportunities
Integrated Branding: Easily includes engraved or embossed logos, text, or patterns during the casting process.
Durability: Cast logos are permanent, withstanding wear and harsh environments.
9. Environmentally Friendly
Uses recyclable materials, including stainless steel and wax molds.
Reduces waste and promotes sustainable manufacturing practices.
10. Versatility in Applications
The process is suitable for various parts, not just switch covers.
We have strong processing capabilities, and the workshop is equipped with a fully automatic production line. Each fully automatic waxing machine can produce 4,000 wax models per day, which is three times the production efficiency of traditional manual waxing machines.
In order to ensure the quality of our products, we have professional material testing equipment (spectrometer). Material testing will be carried out before casting, and the finished castings will be tested twice to achieve perfect material quality and fully meet the material standards required by customers.
