About Investment Casting

Investment casting, also known as lost wax casting, is a manufacturing process in which a wax pattern is created and then coated with a ceramic slurry to create a mold. The wax is then melted out of the ceramic mold and molten metal is poured into the ceramic mold cavity. The molten metal solidifies and the ceramic shell is then broken or blasted off, creating a metal casting. The investment casting process does not require a minimum order quantity and can cast parts ranging from a few ounces to upwards of 200 kgs, so it can be a manufacturing solution no matter what size project you are working on.

Investment casting offers several advantages, including the ability to produce complex shapes with high accuracy, excellent surface finishes, and the capability to use a wide range of metals and alloys. It's commonly used in industries such as Aerospace, Automotive, Oil & Gas, General Engineering, Medical Equipment manufacturing and others Industries.

Manufacturing Process

Investment casting, also known as lost-wax casting, is a manufacturing process used to create complex geometry of metal parts with high precision and intricate details. Here's how it works:

Simulation

Simulates the casting process in advance, eliminating multiple trials and achieving high quality at the first time.

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Tool Design

Automated to produce patterns efficiently and provide dimensionally consistent patterns.

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Wax Pattern

The process begins with the creation of a pattern, which is a replica of the desired part. This pattern can be made from wax material. It's usually made using a mold or by machining.

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Wax Pattern Assembly

Multiple patterns may be assembled onto a central wax gating system, forming a cluster known as the "tree." This gating system allows for the flow of molten metal into the cavity created by the pattern.

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Ceramic Shell

The process begins with the creation of a pattern, which is a replica of the desired part. This pattern can be made from wax material. It's usually made using a mold or by machining.

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De-Waxing

The process begins with the creation of a pattern, which is a replica of the desired part. This pattern can be made from wax material. It's usually made using a mold or by machining.

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Shell Backing

The process begins with the creation of a pattern, which is a replica of the desired part. This pattern can be made from wax material. It's usually made using a mold or by machining.

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Pouring

Molten metal is poured into the cavity left by the pattern. The metal fills the space, taking on the exact shape and details of the original pattern.

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Shell & Gates Remove

Molten metal is poured into the cavity left by the pattern. The metal fills the space, taking on the exact shape and details of the original pattern.

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Finishing

Molten metal is poured into the cavity left by the pattern. The metal fills the space, taking on the exact shape and details of the original pattern.

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Value-Added Operations

Molten metal is poured into the cavity left by the pattern. The metal fills the space, taking on the exact shape and details of the original pattern.

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Delivery

Molten metal is poured into the cavity left by the pattern. The metal fills the space, taking on the exact shape and details of the original pattern.

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Benefits of Investment Casting

The advantages of investment casting are impressive. Create almost any configuration of your precision metal component with High Dimensional Accurcy and Superior surface finishing at very compitative cost. A Design parts as small, large, or complex as you need. In short, eliminate many of the barriers holding you back today.

Consider the following investment casting benefits, which can also help you:

  • Complex Geometry: Investment casting allows for intricate and complex shapes to be easily produced. This is because the process involves creating a wax pattern that can be molded into almost any form.
  • High Accuracy and Fine Detail: It can achieve high dimensional accuracy and excellent surface finish, making it suitable for parts with intricate details and tight tolerances.
  • Versatility: Investment casting can be used to cast various metals and alloys, including steel, aluminum, bronze, and others, providing versatility in material selection for different applications.
  • Minimal Material Waste: Since the process uses a wax pattern that can be melted and reused, there is minimal material wastage compared to other casting methods.
  • Cost-Effective for Small to Medium Batch Sizes: While it may not be as economical as some high-volume manufacturing methods like die casting for large quantities, investment casting can be very cost-effective for small to medium batch sizes due to its ability to produce complex parts without the need for expensive tooling.
  • Smooth Surface Finish: Investment casting typically yields smooth surface finishes, reducing the need for extensive post-processing.
  • Reduced Machining Requirements: Parts produced through investment casting often require minimal machining or finishing operations, saving time and costs in the manufacturing process.
  • Design Flexibility: Design changes can be easily accommodated by modifying the wax pattern, allowing for flexibility in product design iterations.
  • Material Properties: Investment casting allows for the use of a wide range of materials, enabling manufacturers to select the most suitable alloy for the desired mechanical properties, corrosion resistance, and other performance characteristics.
  • Suitable for High-Performance Applications: The ability to produce parts with complex shapes and superior surface finishes makes investment casting suitable for high-performance applications in industries such as aerospace, automotive, and medical devices where precision and reliability are critical.