Our Casting Process

Precision, tradition, and technical excellence in every pour.

Industrial & Aerospace

Maintain consistent wall thickness (preferably > .060). Avoid excessive fillets or heavy sections to reduce costs.

An injection tool is cut from 6061 aluminum based on your IGES file or blueprint.

The die is injected with warm paste wax. Patterns are cleaned by hand and assembled into a "tree" for optimal flow.

Colloidal shell system: Several coats of silica sand are built around the wax set-up over several days.

Steam melts the wax in an autodave. Shells are then heated to 1800°F to prevent thermal shock.

Molten steel alloy (approx 3000°F) is poured into the hot shell immediately after removal from the oven.

Ceramic shell is removed, gating is cut, and parts are ground to the final net shape.

Staff Engineers analyze the sculpture to determine the best layout and sectioning for mold making.

Rubber layers and a fiberglass "mother mold" are created to preserve every detail of the original.

Wax is slushed into the cavity and cleaned. Gating (sprues) are engineered to ensure a perfect casting.

Zircon flower/sand dipping repeated 5-7 times. Steam de-waxing in an Autodave creates the perfect negative.

Shell is pre-heated to 1400°F. Bronze is heated to 2000°F and poured into the hollow shell.

Gating removed, parts welded and assembled, then sandblasted for surface preparation.

Custom coloring using acids and heat. Final seal with paste wax, lacquer, or hi-gloss enamel.