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Produce wax patterns: Although called wax patterns, pattern materials may also include plastic and frozen mercury. [6] Wax patterns can be produced in one of two ways. In one process, the wax is poured into the mould and swished around until an even coating, usually about 3 mm (0.12 in) thick, covers the inner surface of the mould.
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Lost-foam casting – Polystyrene pattern with a mixture of ceramic and sand mold. Investment casting – Wax or similar sacrificial pattern with a ceramic mold. Ceramic mold casting – Plaster mold. V-process casting – Vacuum with thermoformed plastic to form sand molds. No moisture, clay or resin required. Die casting – Metal mold.
Like sand casting, plaster mold casting is an expendable mold process, however it can only be used with non-ferrous materials. It is used for castings as small as 30 g (1 oz) to as large as 7–10 kg (15–22 lb). Generally, the form takes less than a week to prepare. Production rates of 1–10 units/hr can be achieved with plaster molds. [1] [2]
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