A rapid prototype master pattern is created from a 3D CAD file.
Master pattern is inspected against CAD file dimensions to ensure accuracy.
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
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
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.
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.
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.