Master Pattern
A rapid prototype master pattern is created from an .STL file.
Inspection
Master pattern is inspected against CAD file dimensions to ensure accuracy.
Pattern Tooling
Master pattern is placed on a parting board to establish the parting lines of future molds. A temporary rubber negative is then made of the master pattern. The permanent rubber positive is created from the rubber negatives. This allows for duplicate prototypes or short-run multiples.
Plaster Mold
A plaster slurry is poured over the rubber positive tooling to produce a plaster mold. This plaster mold is placed in an oven for 12-14 hours to ensure that all moisture is removed.
Metal Part
After curing, both halves of the plaster mold are assembled and the cavity is filled with a wide range of aluminum or zinc alloys. Once the metal cools and solidifys, the plaster is broken away from the casting and disposed of.
Trim
The gates and sprues are removed. The casting goes through a visual check and straightening process prior to being inspected.
First Article Inspection
The cast part is physically and dimensionally inspected.
Secondary Operations
Several secondary operations can be performed on the part. These additional operations include: heat treatment, machining, chemical film, chromate conversion, paint, special finishes, and assembly.