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die cast process
Understanding Virocast process From our first conversation to your delivered product


our process

  • Discovery

Discovery call

We find our most successful projects start with a simple conversation about your initial business needs, from which we can work out the requirements for your design. The idea is to understand your requirements and answer any questions you may have. After the discovery call, we will summarise the objectives of your project.

  • Are we a good fit?

Following our discovery call, we will confirm if we are able to help. Most of the time, we will be able to assist you, but we do have selective criteria when working on new projects. Therefore, some projects may not be right for us. If we are unable to help, we will do our best to recommend places where you can find help. If we are a good fit and you would like to proceed with our proposal, we will prepare an initial estimation. In some cases, we may need to arrange for an extra call or ask further questions by email.

  • Initial Estimation

At this step, we will provide you with a quote.

  • Scoping Session

The scoping session is of great value to all parties as it enables your company to get a full technical proposal and helps us to assess the technical and commercial objectives of your project.

The session consists of two phases:

1. A scoping session which is held either face-to-face or via a video conference.

2. An internal scoping workshop with Virocast Team.

During the session, you will have an opportunity to talk to our project managers who will analyse your project. The project managers will ask you a number of questions regarding the desired end-use product and request any materials which have been produced in association with your project that can support your case. Apart from gathering information for an internal review, the project managers will highlight any risks and prioritise tasks in relation to your project. You will also be able to ask any questions, share similar projects and raise any concerns.

After the call, an internal workshop will take place to estimate the complexity of each requirement, the expected timeframe and possible risks. The internal workshop is held between the project managers and the head of production.

Within 2 to 5 working days, we will provide a technical proposal highlighting costs and effort breakdowns and a summary of recommendations, risks and insights from our team. At this stage, you should be able to get a good understanding of how we plan to approach your production and what the project will cost based on the scope of work we have identified.

Following this technical proposal, if you decide to work with us, we will finalise the scope of the project and send you our master services agreement.

  • Agreement

Our agreement strictly corresponds to our agile production process. There is a number of points discussed individually with each customer. 

All the points make the process clear and transparent. You have an insight into the duration of each production task and pay only for the real development time. It is a zero-waste strategy for both parties.

  • Deposit

Following the agreement, we will ask for a deposit to be paid based on the agreed scope of work.

This deposit will be applied to your final invoice.




production mould tooling

  • Project kick-off meeting

This is the point at which the project actually begins. Depending on the project’s complexity, a project kick-off meeting can take from one to several hours to fulfil the agenda.

  • Manufacturing of the Tooling

At this stage, depending on the contractual arrangements, we begin working on the tooling design according to the agreed schedule. After joint acceptance of the prepared documentation, we start the production process on CNC machining centres.

Some of the contractors supply moulds together with trimming tools to Virocast themselves. In this case, we review the received tools and adapt them to our foundry machines.

  • Manufacturing of sample product

After the inspection of your tools, they are installed on high pressure die casting or injection moulding machines in order to make sample products for the contractor.

After accepting the sample product, we are ready to start the scheduled mass production.

  • Mass production

Production is carried out in accordance with the previously agreed technical guidelines.

Our clients are always welcome at the Virocast plant to check the progress of their production. For this purpose, we offer cyclical production meetings, which may take place during personal visits or through video conferences.

  • Delivery

Worldwide shipment.

Our main production facility is located in central Europe, creating the possibility of ideal and fast road and sea transport to all countries.

We think that a conversation, in which we can exchange ideas and discuss your business requirements is a critical first step towards achieving the project’s success.