MOLD CREATION
Primarily we create molds and products for the aerospace and medical industries, although we are capable of applying the technology to a wide variety of industries from Architectural applications like signage and decorative motifs to the creation of parts for manufacturing.
We use many techniques both old and new to achieve results. The cornerstone of our process is the creation of wax injection molds. We create wax molds used in a lost wax process, which is a method of metal casting in which a molten metal is poured into a mold that has been created by means of a wax model. Once the mold is made, the wax model is melted and drained away. A hollow core can be created by the introduction of a heat-proof core that prevents the molten metal from filling the mold. The lost-wax method dates back almost five thousand years and has sustained few changes since then.
An example of our process might look something like this. Our client provides a model of a core die. We create ceramic core die and fire it. This becomes the interior cavity that will form the hollow center of the part. To do this, a ceramic imprint of the design is created. This is a negative impression of the model provided. We use this negative to create the green core die and fire it. Second we place the ceramic core die inside the wax tool (the tool is the mold part of the process) injecting wax around the core. Third, we use the lost wax technique to create the new tool. Lastly, we remove the ceramic core, which is used to maintain dimensional tolerances for the internal passages during the casting. The process is especially suited for dissolving porous ceramic cores that are used in internal passages in turbine airfoils where a high degree of precision is required.
Then the product will be inspected using capture 3D, CMM, & RAM Optical to insure the specifications from the original model are adhered to before moving into full production of the part.