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Plaster Casting Process

1) Tooling Engineering & Design: Precise Cast converts 3-D CAD data into a master pattern. Gating (rigging) and shrink compensation are factored into the CAD during this tooling design phase. Depending on part geometry, FEA solidification analysis is run to optimize the tooling design.

2) Tooling: A 3-D solid model is used to machine a master pattern.

3) Pour Silicone Tool: Tooling life depends on a number of factors including part geometry, draft, etc.

4) Form the Mold: A plaster mixture is poured into the tool to form the mold (die). After the mold is firm, the mold halves (cope and drag) are removed from the tool, carefully assembled into a complete mold, serialized, and dried.

5) Pour the Metal: A gravity pour method of filling the cavity is used. Variables that affect casting quality are carefully controlled. These variables include metal temperature, mold temperature, cooling rate, mold tilt, riser size and location, and metal filtering. We use rotary degassing, a continuous melt furnace, and employ a reduced atmospheric testing system to ensure optimal results.

6) Break Out: After the metal has solidified, the mold material is carefully broken away to reveal the metal casting.

7) Parts Cleaning: Next comes the removal of gates, chills, runners, and minor casting imperfections. The result is a “raw” casting.

8) Machining: Final machining is often used to create high-tolerance geometries that are either beyond the capabilities or not economical to incorporate into the casting process. We have a machining department dedicated to the machining of castings. Our technology includes multi-axis capability and probe technology to ensure consistent and accurate machining of each casting.