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Custom Tungsten Heavy Alloy Components

You design it, we produce it. DENSRAM® sintered tungsten heavy alloys: precision-manufactured to your drawing in Switzerland, with full engineering support from prototype to series.

Sintered tungsten heavy alloys, engineered for your application

As a privileged supplier to the world's leading high-voltage switchgear manufacturers, Casram has acquired unmatched expertise in custom tungsten heavy alloy manufacturing. Our proprietary DENSRAM® family combines the extreme density of tungsten with the mechanical resilience of a NiFe or NiCu binder phase: sintered and machined to your exact specifications.

From alloy specification to precision machining and finishing, every component is engineered and quality-controlled at our facility in Switzerland.

Ultra-High Density: 17.0 to 18.5 g/cm³, significantly higher than lead (11.3 g/cm³), enabling compact, high-mass components.
Excellent Machinability: The NiFe or NiCu binder phase enables complex geometries and tight tolerances via conventional CNC machining.
High Mechanical Strength: Tensile strength up to 850 MPa combined with high Young's modulus provides outstanding structural rigidity.
Non-Magnetic Option: NiCu-based DENSRAM® grades deliver identical density performance without magnetic interference.
Radiation Shielding: High atomic number and density make DENSRAM® an ideal material for X-ray and gamma ray attenuation.

Ready to discuss your tungsten heavy alloy project?

Send us your drawings or specifications. Our engineering team will review your project and get back to you with a tailored proposal, typically within 48 hours.

Request a quote

By email: tomas.bocco@casram.com

Or call us directly: +41 91 611 21 10

Integrated manufacturing, every shape possible

From a 5-gram insert to a 50-kilogram shielding block, Casram manages the entire production chain: from engineering to finished part. Seven specialized processes work in concert; giving us the flexibility to produce the most complex geometries, in any DENSRAM® composition, at any scale.

CNC Machining: 15+ machining centres with 3-axis and 5-axis simultaneous milling, live-tool lathe turning: from rapid prototyping to high-volume production runs.
Sintering / Powder Metallurgy: Proprietary sintering specifications for DENSRAM® and COPRAM® alloys: from powder selection and blending through liquid-phase sintering to full-density compacts.
Electron Beam Welding: 24 kW / 60 kV EB welder delivering oxide-free, zero-porosity joints with up to 35 mm penetration in a single pass: ideal for copper and dissimilar metals.
Brazing, Welding & Back-casting: Flame and induction brazing, conventional welding, and our unique back-casting technique for creating perfectly bonded W-Cu composites from impregnated tungsten sponge.
Surface Treatments & Coatings: Passivation, electropolishing, neutralization, galvanic coatings, and heat treatments; complete surface engineering controlled in-house for full traceability.
Assembly & Quality Control: Ready-to-integrate subassemblies with 3D inspection reports, electron microscopy, X-ray spectrometry, and automated ultrasonic inspection of welded joints.

DENSRAM® tungsten alloy grades

Available in NiFe (slightly magnetic) and NiCu (non-magnetic) binder compositions, DENSRAM® alloys meet AMS-T-21014 and ASTM B 777-07 standards. Every grade can be machined to your drawing. Our integrated R&D can also develop custom alloy compositions for unique application requirements.

Alloy	Magnetic Property	Composition	Tensile Strength	Standard Class Grade	Density
DENSRAM® F1	Slightly Magnetic	W 90%, bal. NiFe	≥ 760 MPa	Class 1	17.0 g/cm³
DENSRAM® F2	Slightly Magnetic	W 93%, bal. NiFe	≥ 760 MPa	Class 2	17.6 g/cm³
DENSRAM® F3	Slightly Magnetic	W 95%, bal. NiFe	≥ 730 MPa	Class 3	18.0 g/cm³
DENSRAM® F4	Slightly Magnetic	W 97%, bal. NiFe	≥ 690 MPa	Class 4	18.5 g/cm³
DENSRAM® C1	Non-Magnetic	W 90%, bal. NiCu	≥ 760 MPa	Class 1	17.0 g/cm³
DENSRAM® C2	Non-Magnetic	W 93%, bal. NiCu	≥ 760 MPa	Class 2	17.6 g/cm³
DENSRAM® C3	Non-Magnetic	W 95%, bal. NiCu	≥ 730 MPa	Class 3	18.0 g/cm³

Tungsten heavy alloy applications

DENSRAM® alloys serve wherever maximum mass in minimum volume is critical: from flight-safety aerospace components to precision radiation shielding in medical and nuclear environments.

Aerospace & Defense: Balancing weights for guidance systems, GPS navigation, laser designators, gyroscopic rings, and antenna counterweights; certified to EN 9100.
High Voltage: W-Cu contacts for SF? switchgear, vacuum interrupter contacts in WC-Ag and Cu-Cr, and arc-resistant components for air-break switches.
Nuclear Technology: High-density shielding for gamma and X-ray radiation, collimator components, and containment vessel inserts for reactor applications.
Medical Devices: Radiation therapy collimators, CT scanner counterweights, and shielding elements for imaging equipment; biocompatible and non-toxic.
Railway: Sintered electrical contacts and electromechanical components for rolling stock; serving the rail industry for over 60 years with zero-compromise quality.
Vibration & Balancing: Compact balancing weights for turbines, rotors, and high-speed machinery where space is limited but mass must be maximized.

Tungsten alloy manufacturing: from powder to precision part

Fully managed production ensures traceability and quality at every stage: from raw material specification through final CNC machining and inspection.

Powder Selection: Sourcing ultra-pure tungsten and binder powders to exact specifications
Blending: Precision mixing of W with NiFe or NiCu binder phase in controlled ratios
Pressing: Cold isostatic or dry-bag pressing to form near-net-shape green compacts
Sintering: Liquid-phase sintering in hydrogen atmosphere to achieve full density
CNC Machining: 5-axis precision machining, grinding, EDM, and surface treatments to final spec

Your design, our engineering

Casram is not a catalogue supplier; we manufacture tungsten heavy alloy components to your exact technical drawings and specifications. Whether you need a single prototype or a 10,000-piece production run, our vertically integrated facility delivers finished parts ready for assembly.

What sets us apart is our specialized engineering department, which works alongside your design team from the earliest stages. We don't just produce; we help you optimize your component for tungsten heavy alloy manufacturing, advising on material grade selection, tolerance achievability, and cost-effective production strategies.

Send Your Drawing: Share your 2D/3D technical drawings or specifications. We accept all major CAD formats and work to international dimensioning standards.
Engineering Review & Optimization: Our engineers review your design for manufacturability, recommend the optimal DENSRAM® grade, and suggest improvements that reduce cost without compromising performance.
Prototype & Validation: We produce and inspect prototype parts with full dimensional reports, material certificates, and mechanical test data; so you can validate before committing to series.
Series Production & Delivery: Seamless transition to batch or series production with consistent quality, full traceability, and on-time delivery of finished components ready for your assembly line.

Ready to discuss your tungsten heavy alloy project?

Send us your drawings or specifications. Our engineering team will review your project and get back to you with a tailored proposal, typically within 48 hours.

Request a quote

By email: tomas.bocco@casram.com

Or call us directly: +41 91 611 21 10