Prototype/Short-Run Castings
Services: Capital Pattern and Model, Inc. is a leading provider of quality custom prototype and short-run castings in both ferrous and non-ferrous alloys. Our state of the art in-house pattern shop and machine shop together with our network of partner foundries help us to provide quality castings with quick turnaround and short lead times. With Engineering Assistance available, we can work closely with your engineers to help create cost effective casting designs that guide your product from concept to finished parts.
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Casting Materials we handle:
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Capabilities:
- A real "turnkey" solution
- Excellent lead times
- Casting sizes from 1- 1500 pounds
- Prototype and low-volume production quantities (typically 1-1,500 annually)
- Casting of both ferrous and non-ferrous metal alloys
- In-house pattern shop
- In-house machine shop for machining secondary operations
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We use a combination of the following different prototype methods that best suit your project:
Green Sand Method Green Sand is by far the most diversified molding method used in present casting practices. The process utilizes a mold made of compressed or compacted moist sand. The mold material consists of silica sand mixed with a suitable bonding agent (clay) and moisture. If the casting has hollow sections or undercuts, a core consisting of hardened sand is used. Some of the advantages of green sand molding are that most metals can be cast and the pattern costs are relatively low. The method is adaptable to large or small quantities and can be produced quickly.
No-Bake or Air-Set Air-Set molding process utilizes a mold made of silica sand mixed with furan and urethane binders. The binders allow the molder to control the setting times by means of the addition of specific amounts of catalyst. This feature, combined with high strength and desirable range of hot properties for use with various alloys presents the opportunity for great flexibility in mold making. One advantage to this method is better dimensional control. Hollow section and undercuts can be created with the use of cores.
Plaster Molding (simulated die casting)Plaster molding utilizes a mold made from plaster instead of sand. This process is done by pouring liquid plaster over the pattern. The plaster molds then must be dried in ovens for typically 24 hours before metal can be introduced. Plaster molds are strong, relatively precise molds that enable the casting to yield better casting tolerances and thinner wall sections. The use of plaster or sand cores can be used to create hollow sections and undercuts. Plaster molding can be relatively expensive as compared to sand casting but with certain designs this may a necessary method.
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