High quality Aluminium die
- Expected cast tolerances would be ±0.13mm/25mm
- Expected cast surface finish would be 3.2 Ra µm
- Ideal for high volume or high tolerance components
- This tooling is a lower cost option for simpler lower volume production and suits small batch production typically used in manufacturing from existing patterns, automotive restoration or architectural applications
- Rubber tooling is not always the cheapest option or definitively accurate but can produce dramatic results for repeating complex works of art, restoration components and replicas like medals or cast features. It is also the choice for jewellery production.
Prototype printed waxes
- For more info see Newby RapidCast
High dimensional accuracy at economical costs.
Lost Wax Process
- Wax injection
- A precision made die is injected with molten wax. This die incorporates contraction allowances for both the wax and metal.
- Pattern removal
- Once set the wax is removed from the die producing a replica of the finished part. This is called a pattern.
- Pattern assembly
- Quantities of these patterns are joined to a pattern assembly using a hot soldering iron. The assembly holds the individual patterns in place for the remainder of the process.
- Ceramic investment
- The assembly is dipped into a ceramic based slurry, drained of any surplus liquid, covered in a dry ceramic stucco and left to dry. This operation is repeated a number of times until the required shell thickness is obtained.
- The ceramic mould is placed in a high temperature oven to melt the wax from the mould.
- Mould sintering
- The oven also bakes the ceramic shell so that it is strong enough to withstand the molten metal being poured into it.
- Metal pouring
- Metal ingots are heated in an induction furnace to the correct temperature. Once this is obtained the red hot mould is removed from the oven and the molten metal is poured into the ceramic shell.
- Ceramic removal
- After cooling the ceramic is then vibrated from the castings and runner system.
- Finished product
- Finally, the castings are separated from the runner system by means of an abrasive cutting wheel and then finished by means of linishing, grinding and blasting prior to inspection and despatch to the customer.