MERCHANT EXPORTER — FORGING · CASTING · SHEET METAL
ENQUIRIES: info@variexenterprise.com  |  +91 72288 08510
Manufacturing Scope & Expertise

Four specialised manufacturing capabilities. One unified quality benchmark.

We combine advanced Indian manufacturing ecosystems across Sheet Metal Stamping, High-Pressure Aluminium Die Casting, SG/CI Iron Casting, and Closed-Die Forging — delivering custom-engineered components manufactured strictly to your CAD drawings and metallurgical standards.

Jump to: 01. Sheet Metal 02. Die Casting 03. Iron Casting 04. Forging Process Comparison Table →
Core Process Overview

Engineered for global OEM specifications

Explore our key processing methods, operational thresholds, and specialized component capabilities below.

Capability 01 · Stamping & Fabrication

Precision Sheet Metal Fabrication

Custom precision sheet metal forming, high-power fiber laser profiling, 7-axis CNC press brake bending, and robotic MIG/TIG welding. Engineered for tight-tolerance structural brackets, submersible pump cooling covers, electrical enclosures, and commercial vehicle ABS pulse tone rings.

Thickness: 0.5 – 12mm Tolerance: ±0.1mm Bed Size: 2500×1250mm Materials: MS, SS304/316, Al, GI
  • High-speed fiber laser profiling for intricate contours without tooling wear
  • Deep drawing & progressive die stamping for high-volume repetitive parts
  • Surface treatments: automated powder coating, zinc plating & anodizing
Capability 02 · Aluminium HPDC

High-Pressure Aluminium Die Casting

Automated cold-chamber High-Pressure Die Casting (HPDC) cells ranging from 120T to 660T clamping force. Capable of producing thin-walled, high-density, complex-geometry parts with excellent surface finish, supported by dedicated multiaxis CNC/VMC post-machining and CMM verification.

Machines: 120T – 660T HPDC Capacity: 675 MT / Year Part Weight: 0.1g – 6.0kg Min Wall: 1.25mm
  • ISO 9001:2015 certified casting unit with electric holding furnaces (5 nos)
  • Precision VMC/CNC milling & turning with positioning accuracy to 0.003mm
  • Hydrostatic leak testing, millipore cleanliness & surface roughness testing
Capability 03 · Foundry & Machine Shop

SG (Ductile) & CI (Grey) Iron Casting

High-integrity foundry manufacturing in Spheroidal Graphite Ductile Iron (SG / GGG40–70) and Grey Cast Iron (CI / FG200–300). Features automated green sand moulding lines and a 30-machine precision machine shop for high-load automotive brackets, brake drums, and pump casings.

Foundry: 3,600 MT / Year Weight: 0.2kg – 50kg Quality: IATF 16949:2016 Moulding: 45–50 moulds/hr
  • Dual-crucible induction melting with real-time optical emission spectrometry
  • Twin-head pallet-changer VMCs & CNC turning for finish-machined castings
  • Comprehensive metallurgical sand lab, tensile testing & Brinell hardness checks
Capability 04 · Drop & Closed Die

Hot & Closed-Die Steel Forging

Hot and closed-die forging engineered for structural integrity, superior grain flow alignment, and high fatigue resistance. Specialising in carbon steel, alloy steel, and stainless steel industrial flanges (150# to 2500#), high-pressure fittings (3000#/6000#), and automotive transmission shafts.

Capacity: 1,200 MT / Year Weight: 25g – 50kg Presses: 350T Friction / 100T Power Standards: ASME / DIN / EN / BS
  • Standard & custom flanges: Blind, Slip-On, Weld Neck, Threaded (1/2"–32")
  • High-pressure socket-weld & threaded elbows, tees, unions, and swaged nipples
  • Isothermal normalizing, shot blasting, CNC turning & MPI crack detection
Capability 01 · Detailed Scope

Precision Sheet Metal Fabrication & Stamping

Our sheet metal manufacturing facility delivers end-to-end processing from raw sheet shearing to fully finished, coated assemblies. Utilizing high-precision CNC fiber lasers and multi-axis press brakes, we maintain repeatable dimensional accuracy on intricate geometric profiles.

Whether you need low-volume custom prototyping or bulk container export production, our tooling design team works directly from your 2D/3D CAD models (STEP, DXF, IGES, PDF) to optimize nesting efficiency and reduce scrap costs.

0.5–12mm
Thickness Capability
±0.1mm
Linear Tolerance
2500×1250mm
Max Sheet Envelope
2–4 Weeks
Production Lead Time
Detailed Sheet Metal Specifications → View Sheet Metal Catalog

Technical Parameters & Infrastructure

  • Compatible MaterialsMild Steel (CRCA/HR), SS 304/316, Aluminium, Galvanized Steel
  • Laser ProfilingFiber laser cutting with clean-cut nitrogen gas assist
  • Forming CapacityCNC 7-axis synchronised press brakes up to 150T
  • Joining & WeldingMIG, TIG, Projection Welding, Spot & Stud Welding
  • Post-FinishingZinc plating (trivalent), Powder Coating, Anodizing, Buffing

Typical Component Applications

Commercial Vehicle ABS Tone Rings (DAF, MAN, Mercedes, Scania) Submersible Pump Impeller & Fan Covers Elevator Structural Brackets & Panel Clips Agricultural Tiller Blades & Machinery Guards Power Distribution & Inverter Enclosures
Capability 02 · Detailed Scope

High-Pressure Aluminium Die Casting (HPDC)

Operating an ISO 9001:2015 certified aluminium foundry with automated cold chamber HPDC cells from 120 Tons to 660 Tons. We produce lightweight, structural components with uniform grain density, low porosity, and excellent thermal dissipation properties.

Our in-house CNC/VMC machine shop performs second-operation machining including precision milling, tapping, boring, and diamond turning with tolerances down to ±0.015mm, backed by coordinate measuring machine (CMM) dimensional verification.

120T – 660T
HPDC Machine Array
675 MT / Yr
Foundry Melt Output
0.1g – 6.0kg
Individual Casting Weight
±0.05mm / ±0.015mm
Cast / Machined Tolerance
Detailed Die Casting Specifications → View Die Cast Products

HPDC Fleet & Precision Machine Shop

  • HPDC Machine Inventory660T (×1), 250T (×1), 180T (×1), 120T (×2)
  • Melting Furnaces5 Electric holding furnaces (500kg×1, 250kg×2, 400kg×2)
  • VMC FleetHaas VF-2 (USA, 0.003mm repeatability) & BFW 60 T20 (1050×650mm)
  • CNC Turning CentresRIT 600 T (×2, 0.003mm positioning, travel up to 600mm)
  • Trimming & Secondary20T Hydraulic Trimming (×2), 10T Power Press, Shot Blasting
  • Quality & CertificationsISO 9001:2015 (TÜV SÜD), ZED Silver, 3D CMM, Leak Testing

Typical Component Applications

EV Motor Housings & EV Charger Enclosures 3-Wheeler Engine Cylinder Blocks Deep-Fin LED Heat Sink Housings Pneumatic Valve & Vacuum Pump Bodies Clutch Sleeves, Wheel Hubs & Fan Rotors Defense Driven Plates & Aerospace Racks
Capability 03 · Detailed Scope

SG (Ductile) & CI (Grey) Iron Casting

Certified under IATF 16949:2016, our iron foundry specialises in Ductile Spheroidal Graphite Iron (SG / GGG40, GGG50, GGG60) and Grey Cast Iron (CI / FG200, FG260, FG300) engineered for high mechanical damping, impact strength, and wear resistance.

Featuring automated RHINOLINE green sand moulding (45–50 moulds/hr), induction melting (500kg dual + 300kg uni), 250 MT/month precision CNC/VMC machine shop, and an in-house automated CED (Cathodic Electrodeposition) coating plant with salt spray corrosion testing.

3,600 MT / Yr
Annual Foundry Capacity
250 MT / Mo
Machine Shop Output
CED Unit
In-House E-Coating
IATF 16949
Automotive Standard
Detailed Iron Casting Specifications → View Iron Casting Catalog

Foundry, Machining & CED Coating Facilities

  • Melting InfrastructureMedium frequency induction (500kg dual + 300kg uni)
  • Moulding SetupRHINOLINE automated sand line (600×600mm), 3× Core shooters
  • Machine Shop FleetTwin-head pallet VMC (×5), VMC (×12), CNC turning (×6), VTL (×1), SPM (×6)
  • Machining EnvelopeID 18–300mm · OD 10–400mm · Length up to 600mm
  • In-House CED UnitAutomated Cathodic Electrodeposition coating & Salt Spray Lab (ASTM B117)
  • Quality & MetrologyCarl Zeiss 3D CMM, Zeiss Surface Tester, Spectrometer, 4× Leakage Testers

Typical Component Applications

Engine Alternator & Bumper Mounting Brackets Commercial Vehicle Brake Drums & Hubs Multi-Groove V-Pulleys & Idler Hubs Water Pump Bodies & Thermostat Housings Rear Oil Seals & Gear Box Housings Axle Stops & DOC Brackets
Capability 04 · Detailed Scope

Hot & Closed-Die Steel Forging

Hot closed-die drop forging engineered for components requiring maximum tensile strength, uninterrupted metallurgical grain flow, and zero internal porosity. Built to withstand high hydraulic pressure, vibration, and dynamic load-bearing cycles.

Our forging shop operates 350-ton friction presses and heavy power presses, specializing in international pipe flanges (ASME B16.5, EN1092-1, DIN) from 1/2" to 32", high-pressure socket-weld fittings up to 9000 LBS, and automotive driveline components.

1,200 MT / Yr
Annual Forging Output
25g – 50kg
Forged Part Weight
150# – 2500#
Flange Pressure Classes
ASME / DIN / EN
Global Dimension Standards
Detailed Forging Specifications → View Forged Products Catalog

Press Fleet, CNC Machining & Quality Setup

  • Forging Presses350T Friction screw press (×1), 100T power press (×2), 80T (×2)
  • Machining Fleet7 nos. Precision CNC Turning & Machining Centers
  • Machining EnvelopeID 8–300mm · OD 10–400mm · Length 15–200mm (100 MT/mo)
  • Flanges (ASME/DIN/EN)1/2" to 32" · 150# to 2500# (Weld Neck, Slip-On, Blind, RTJ)
  • Fittings (ASME B16.11)1/8" to 4" · 3000#/6000#/9000# (Elbows, Tees, Couplings, Unions)
  • Quality & MetallurgyISO 9001:2015, Spectro analysis, Shot blasting, NDT (MPI/LPT)

Typical Component Applications

Oil & Gas Pipeline Flanges (ASME B16.5 / B16.47) High-Pressure Hydraulic Fittings (3000# / 6000#) Forged Pinion Gears & Transmission Shafts Piston Rods & Round Pins Heavy Commercial Vehicle Drivetrain Components
Direct Comparison Matrix

All four capabilities compared by engineering parameters

Review mechanical capabilities, materials, tolerances, and typical volume parameters to determine the best-fit process for your component.

Capability Material Alloys Dimensional Tolerance Weight / Size Limits Key Infrastructure Secondary Operations Lead Time Certification
01. Sheet Metal Stamping & Fabrication Mild Steel (CRCA/HR), Stainless Steel 304/316, Aluminium, Galvanized Steel ±0.1mm linear
CNC Laser / Bending
Sheet envelope up to 2500×1250mm
Thickness 0.5–12mm
CNC Fiber Lasers, 7-Axis Press Brakes (150T), Robotic MIG/TIG Drilling, tapping, spot welding, powder coating, zinc plating 2–4 weeks ISO 9001:2015
02. Die Casting Aluminium HPDC Aluminium casting alloys (ADC12, LM24, LM6, A380, AlSi9Cu3) ±0.05mm cast
±0.015mm machined
0.1g to 6.0kg
Min wall 1.25mm
120T, 180T, 250T, 660T Cold Chamber HPDC, 5 Holding Furnaces CNC/VMC finishing, 20T hydraulic trim, shot blasting, leak test 3–5 weeks ISO 9001:2015
03. Iron Casting SG & CI Foundry Ductile Iron (SG400/12 to SG700/2), Grey Cast Iron (CI FG200 to FG300) ±0.2mm raw
±0.01mm machined
0.2kg to 50kg
Box: 600×600mm
Induction Furnaces (500kg dual), Green Sand Automated Line, 17 VMCs Twin-head VMC machining, CNC turning, VTL, dynamic balancing 4–6 weeks IATF 16949:2016
04. Forging Closed-Die Steel Carbon Steel (ASTM A105, C45), Alloy Steel (F11, F22, 4140), Stainless Steel ±0.15mm forged
±0.01mm turned
25g to 50kg
Flanges up to 32"
350T Friction Press, 100T Power Presses, Induction Billet Heaters CNC precision turning, thread cutting, normalizing, shot blast, MPI 3–5 weeks ISO 9001:2015
Quality Assurance Protocol

One rigorous inspection framework across every capability

Every component manufactured under our roof passes through documented metallurgical and dimensional checkpoints before export clearance.

STAGE 01

Raw Material Verification

Spectrographic chemical alloy analysis, mill test certificate (MTC) validation, and ultrasonic flaw testing before melting or cutting begins.

STAGE 02

First-Piece & In-Process QA

Dimensional sign-off on first-off parts and periodic statistical sampling during stamping, casting, forging, and CNC machining cycles.

STAGE 03

Final Inspection & Testing

100% critical-dimension checks, 3D CMM reports, surface roughness (Ra/Rz), hydrostatic pressure/leak testing, and MPI crack detection.

STAGE 04

Export Packaging & Dispatch

Anti-rust VCI preservation coating, heavy-duty seaworthy euro-pallet crating, barcoded lot traceability, and comprehensive customs documentation.

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