Wax Pattern Injection Molds
Wax pattern injection molds are machined in our mold making department. We use the latest CAD/CAM and have master mold makers with more than 20 years of experience. Mold Making
Wax pattern molds are carefully checked for compliance to all detail. All pattern molds are maintained to the highest standards and are ready for use when the customer places an order for castings. Wax Pattern Injection
Wax patterns are produced by injecting liquid or paste wax into the mold. When the mold is opened, the wax pattern is removed and includes all the detail of the final part. Wax Patterns
A number of wax patterns are injected to make up a production lot. Wax Patterns
The wax patterns are carefully inspected for defects. If a defect is found, the pattern is either repaired or scraped as only acceptable patterns can move on to the next operation. Pattern Assemblies
Multiple wax patterns are assembled on a frame or a more commonly referred to as a tree. Ceramic Shell, Prime Slurry
The wax assemblies are coated with a fine ceramic liquid called Slurry. Application of Sand
The wax assembly is then covered with a fine sand while the slurry is still wet. Great care must be taken at this stage to make sure the entire part has been covered completely with sand. Drying Time
The wax assembly with a fresh coat of ceramic must dry before moving onto the next dip. Typically the parts will be left to dry for about 24 hours but could be longer depending on the part configuration. Shell Slurry and Sand
Subsequent layers of slurry and sand is applied to build a thin ceramic shell. Additional Drying Time
After each layer of slurry and sand the shell is allowed to dry completely to make a strong ceramic shell. Completed Ceramic Shells
Finished ceramic shells are now ready for the next process to remove the wax from the inside of the shell. Autoclave De-wax
Ceramic shells are processed in steam autoclave to melt the wax out. High Temperature Burnout
De-waxed shells are put into an oven that is heated up to 1600 - 1800 F to burnout residual wax and to cure the ceramic. Fired Ceramic Molds
Fired ceramic molds are now ready to be preheated for the pouring of the molten metal. Metal Casting
Metal is melted in crucible lined furnaces. The preparation of molten metal is critical to the casting quality. Once the metal has been melted and degassed it is ready to pour. The metal is poured by hand into the ceramic mold. Post Cast Ceramic Shell
The metal casting has now taken the shape of the wax pattern and assembly. After the assembly cools to room temperature, the shell will be removed. Shell Removal
Ceramic is removed from the cast metal Assemblies using high pressure water. Cut Off
Saws are used to remove the unwanted gates and risers. Gate Grinding
Gates are further removed by rough grinding them on a belt sander. Finishing the Casting
Any other de-burring or hand finishing can be done at this time. Heat Treating
Subsequent processing usually includes heat treating to improve the physical properties of the alloy castings. Sand Blast Finish
In most cases a sand blast finish is used to blend the surfaces and present a clean and uniform finish. Fluorescent Penetrate Inspection
Fluorescent Penetrate Inspection may be required when castings must meet strict MIL-spec's. This non-destructive testing process will detect surface flaws, that may not be visual to the eye. X-Ray
Further NDT may also be required by the specification. X-ray may be used to detect flaws below the surface of the casting. Test Bars
Mechanical properties are determined by pulling a test bar on a tensile testing machine. The machine measures the amount of force that is required to break the test bar. Spectrometer
A Spectrometer is used to check the chemistry of every casting lot to determine that all parts produced meet the customers specifications. Dimensional Inspection
Dimensional characteristics can be measured 100% for compliance by CMM and hand measuring tools. Secondary Machining
We also have in house CNC machining capabilities dedicated to providing our customers with precision machined castings. Custom Packaging Parts
Each and every part is evaluated for packaging to ensure that your parts arrive without damage. The Investment Casting Experience
Here you can see that the final cast part is identical to the injected pattern in every detail. Send Us Your Casting Challenge
Let the experts at AlCuMet, Inc. evaluate your casting requirements. We can take your next project from rapid prototype through low, medium or high volume production..