Precision Sand Casting
Precision Sand Casting is the simplest and most versatile of the processes used to cast aluminum. Precision Sand Casting can frequently meet the service requirements of the casting at a cost lower than that of other construction methods. Generally, there are very few size limitations on sand castings: they can range in weight from a few ounces to 100 pounds and are usually confined to producing parts that have thicker wall sections and require more draft on geometry that is perpendicular to the parting line. The Precision Sand Casting process is often chosen for the production of small quantities of simple castings with few cores, and large structural castings.
Our skilled craftsmen have years of experience in making patterns to exacting tolerances in wood or plastic via traditional methods.
The pattern on the right is a fabricated wood/plastic pattern that is primed and sanded to a smooth finish.
Another option is to create patterns in plastic, using your CAD generated data through CNC Machining in a "subtractive" process.
The pattern to the right is a machined pattern from polyurethane foam board. It will be coated with a primer then sanded to a smooth finish.
We can create patterns in plastic, using your CAD generated data through StereoLithography. SLA patterns are made in a method of rapid prototyping which converts 3-D CAD data into a series of very thin slices or cross sections and uses a laser-generated ultraviolet light beam to trace each layer onto the surface of a vat of liquid polymer. As the laser hits the photopolymer it is catalyzed, subsequently forming, hardening and bonding each layer until the complete, full-size pattern is formed. The SLA pattern will be coated with a primer then sanded to a smooth finish.
Nearly any geometry imaginable can be created with this "additive" process including closed or trapped volumes. An advantage over machining is that there are no additional set-ups required to form the "underside" of the part and no radius allowance is required for square corners. Additionally patterns of high complexity can be created with a high degree of accuracy.
Once the patterns are created and coated, the visible difference is hard to see.
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