We're Refined: Following a consistent and efficient casting process that saves time and money on your project.

Craft Cast Company, LLC

The Lost Wax Casting Process


cad and comuters used when designing

Design

All castings start out with the customer's plans, blueprints, or specifications. Our experienced engineers work out design details with the customer and develop computer models of the cast part. Since every application has different requirements, our personnel are an invaluable resource in answering questions and providing design information.

prototyping equipment

Prototyping

We can take your concept design to reality using various methods. You can have a preview of your final product using CAD modeling and any number of pattern making techniques such as Thermo jet patterns, SLA's, foam, or simple prototype dies. The path chosen is driven by customer specific needs and requirements.

pattern example

Pattern

For every casting a wax pattern must be manufactured. By injecting wax into an aluminum die, a pattern is formed that is the exact replica of the part to be produced. The die can be manually operated to fully automatic, depending on the customer's requirements.

assembly equipment

Assembly

The wax pattern is then attached to a large runner system called a tree. Many patterns are attached to the tree forming a cluster. A ceramic pouring cup, which will receive the molten metal, is attached to the top of the tree.

pattern being dipped

Investing & Stuccoing

The assembly of patterns is dipped repeatedly into an agitated vat of ceramic slurry (investment), drained, coated with a fine silica sand (stuccoing), and allowed to dry. This process is repeated using progressively coarser grades of sand until a self-supporting shell (approximately 3/8" thick) has been formed.

Dewaxed part

De-waxing

Once the shell has dried, it is placed into an autoclave where pressure and steam-heat remove the wax, leaving a hollow mold for casting.

pusher oven used for firing

Firing

The hollow molds are placed in a firing furnace and preheated to 1800 degrees Fahrenheit in order to crystallize the shell and prepare it to receive the molten metal.

alloys being poured into molds

Casting

Molten metal is then poured or cast immediately into the preheated molds. After the molds have cooled, the ceramic shells are removed from the casting by mechanical vibration, blasting and chemical cleaning.

part being hand ground

Finishing

Parts are then cut from the assembled clusters and finished using a variety of cleaning operations similar to other casting processes. While some castings may be ready for use at this point, others require secondary operations including machining, polishing, plating, etc.

inspection station

Inspection

Inspection is performed manually and using a computerized coordinate measuring machine to verify casting conformance to customer requirements. Craft Cast uses SPC methods to ensure consistent performance in all critical processes.