Machined molds are time-consuming and costly if you only need development engineering prototypes to prove out and verify your design, or low volume quantities. Wax is then injected into the machined aluminum molds to create multiple investment casting wax patterns. Multiple-cavity molds are made for high-volume production quantities. Single cavity molds are produced for low-volume production runs. In production wax injection molds are machined from billet aluminum blocks. Wax patterns can be manufactured using a variety of techniques. As with all metal castings machining stock is added to areas requiring close tolerances not achievable in the “as cast” form. Once the metal solidifies the casting is removed from the mold by breaking the plaster away from around the part and consequently destroying the mold. The foundry then pours the metal into the plaster mold. Plaster slurry is then poured over the rubber positive to produce the plaster mold. This master is used to produce a temporary rubber negative which, in turn is used to produce a final rubber positive. Typically an SLA (stereolithography) model is made of the actual part using “as cast” CAD geometry. Today the pattern master is produced using rapid prototype (RP) technologies. Instead, the plaster mold process begins by using a pattern master. Investment casters who use the plaster mold process do not require a wax patterns. The rubber plaster molding process also serves as a short run (<2,000 /year) production process for programs that cannot justify the cost of hard tooling.Ĭastings from the rubber plaster mold process feature excellent surface finishes, complex geometry (including undercuts and complex coring). Tooling is low cost and easily accommodates geometry modifications and design enhancements. This process is both suitable for short run production quantities of aluminum and zinc parts.Ĭastings from plaster molds simulate die cast parts for appearance and properties. The rubber plaster mold process offers an alternative to ceramic investment casting, sand casting and prototype die casting. Aluminum or zinc parts can be shipped in as little as 2-5 weeks from receipt of 3D CAD part geometry, depending on size and quantity. This is the best process to simulate aluminum or zinc die cast parts in both properties and appearance. The metal part is then ready for machining and finishing operations. Molten metal is poured (cast) into the mold, forming the final part. When fired the wax pattern will liquefy and completely melt out of the mold leaving a hollowed out form representing the final part geometry. A high quality wax will leave no ash after burn out to contaminate the metal casting. Quality formulations of wax provide a stable and accurate pattern media. Wax as a pattern media is a used universally throughout the investment casting and jewelry industry. The investment casting process begins with an investment casting pattern typically made of custom-formulated foundry wax. Today it is often used to rapid prototype metal parts. ![]() The metal casting manufacturing process is also known as lost wax. Investment castings are well suited for both long and short runs, and are typically recommended for applications in which fine detail, design complexity and accuracy are required. In both processes the wax is liquefied and burns off. ![]() The ceramic mold is fired in a furnace to drive out moisture. Production molds used to manufacture metal investment castings are commonly made using either ceramic or plaster. The process can yield production accuracies of +/. Prototype and low quantities of metal investment castings are typically produced from a tooling master and specialty wax patterns. Today this experience provides Rapid Designs customers with access to the highest quality makers of investment castings as well as expert advice on the appropriateness of investment castings versus other approaches in the spectrum of product development processes. Rapid Designs team of specialists provides special expertise in investment castings, based on the company's origins 40 years ago as a model and pattern maker for the foundry industry. Rapid Designs offers expert advice as well as attentive service in the production and utilization of investment castings as part of its fully-integrated product development and rapid manufacturing services. Investment Casting Investment Castings – Rapid Designs Provides a “Rapid Prototyping Bridge to Production” Metal Casting Solution
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