Investment casting process
For small parts made of aluminum, steel and cast iron
Extremely thin wall thicknesses, accelerated mold production and very fine surfaces – for small parts with complex geometry, investment casting offers numerous benefits compared to other production processes. At ACTech we have further optimized our investment casting process and supplemented it with patented technologies: working with us means we set new standards for you in terms of speed, quality and complexity.
Small parts made of metal are often produced using CNC milling. However, highly complex, filigree parts mean this process reaches its limits. Hence ACTech relies on investment casting: It enables us to realize even the most complex geometries in record time and achieve significantly higher quality levels. Depending on the alloy, quantity, geometry and desired surface finish, we initially produce a detailed pattern of your part from wax or polystyrene. This forms the basis for mold production using the plaster mold- or ceramic mold process. The plaster mold process enables maximum speed when producing molds. This is achieved by casting the model in plaster compound in a prefabricated cell.
In the subsequent thermal process, the mold is cured and the pattern is simultaneously melted out. The plaster mold can then be directly used for investment casting, whereby all types of cast aluminum alloys can be processed. For even greater flexibility in the selection of materials, the ceramic mold process is recommended: Here, the pattern is first dipped in a slurry and sanded layer by layer before the firing process and melting out process are implemented in parallel. The specific number of layers depends on the desired alloy and is determined individually. Almost all materials from our material portfolio can be cast with these molds.
ACTech sets new standards in investment casting: Depending on the material and component geometry, we achieve extremely thin wall thicknesses of down to 1.5 mm – thus expanding industry-standard limits for prototype casting. Through the targeted use of high-precision polystyrene and wax patterns (also in combination), we also produce castings with above-average surface finish. This reduces machining to a minimum and your batch-comparable part is ready for use even faster.
Highly complex geometries and filigree parts are our mission, and more than 230,000 metal prototypes produced speak for themselves. Based on this experience, we develop individual, fast and deadline-compliant investment casting solutions for you in above-average quality – even for completely new, unprecedented part variations. You are also always in safe hands with us: Live tracking of the production status and direct communication with our project management promise maximum levels of transparency and control.
For small, filigree parts with fine surfaces, investment casting guarantees speed and quality. However, that by itself is not enough for us. This is why we have developed a patented drying process for the ceramic mold process. This enables us to further reduce drying time during mold production.
What is the maximum size of parts in investment casting?
The maximum size for parts in investment casting is determined by two parameters: the size of the plaster cell and the weight of the part. For this reason, our project managers assess as part of their feasibility check whether your part is suitable for investment casting or whether you would benefit more from a different process even before we draw up a quotation. Therefore, don't hesitate to contact us in this matter.