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Low-Volume/Prototypes
SLA
SLS
ColorJet Printing (CJP - ZPrint)
MultiJet Printing (MJP - ProJet)
Manufactured Plastic Prototypes
QuickPlastic™ Cast Urethanes
Plastic Jet Printing (PJP)
CNC Machined Parts
Quick Sheet Metal™
QuickMetal™ Plaster Mold Casting
Process
Casting Tolerances
Metal Casting
Process Details
Quality Control
Lead Time Options
Prototyping Sample Kit
QuickMetal™ Plaster Mold Casting Process
Step Description

Master Pattern

A rapid prototype master pattern is created from a 3D CAD file.

Inspection

Master pattern is inspected against CAD file dimensions to ensure accuracy.

Pattern Tooling

Master pattern is placed on a parting board to establish the parting lines of future molds.
A temporary rubber negative is then made of the master pattern.  The permanent rubber 
positive is created from the rubber negatives.  This allows for duplicate prototypes or 
short-run multiples.

Plaster Mold

A plaster slurry is poured over the rubber positive tooling to produce a plaster mold.  
This plaster mold is placed in an oven for 12-14 hours to ensure that all moisture
is removed.

Casting

After curing, both halves of the plaster mold are assembled and the cavity is filled with
a wide range of aluminum or zinc alloys.  Once the metal cools and solidifys, the plaster
is broken away from the casting and disposed of.

Trim

The gates and sprues are removed.  The casting goes through a visual check and 
straightening process prior to being inspected.

First Article Inspection

The cast part is physically and dimensionally inspected.

Secondary Operations

Several secondary operations can be performed on the part.  These additional 
operations include: heat treatment, machining, chemical film, chromate conversion, 
paint, special finishes, and assembly. 


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