Utilization of the investment casting process can reduce your component weight and in some cases, eliminate costly machining. Investment casting is a process where a wax pattern is used to shape a disposable ceramic mold, which in turn has molten metal cast into it.
Investment casting provides a high degree of flexibility to cast complex design with intricate features, such as through holes, slots, and complicated profiles. When correctly utilized, this process can reduce your component weight and in some cases, eliminate costly machining by producing net shape or near net shape parts. Very thin sections can be produced by this process - metal castings with sections as narrow as 0.015 in (0.4 mm) have been manufactured using investment casting. Investment casting also allows for high dimensional accuracy - tolerances as low as 0.003 in (0.076 mm) have been claimed. Hence, we see this process being used in industries such as aerospace, medical devices, sports equipment etc.
Zetwerk utilizes both gravity fed and vacuum casting methods to produce components that range in weight from a few grams up to 30 kgs.
Zetwerk offers a range of materials that can be investment cast. We work with carbon steel, low alloy steel, stainless steel grades, and various super alloys, in addition to a wide variety of non-ferrous metals, such as aluminum, brass, bronze, copper and many more.
Typically, we use a machined aluminum tool/mold is created (negative of the final metal part) and wax is injected into the mold to create a pattern, which is a positive of the final metal part. Alternatively, the pattern can also be 3D printed in wax for rapid prototyping. A 3D printed wax pattern allows for complex designs which otherwise aren’t possible to mold using an aluminum tool.
Zetwerk has the resources to finish machine investment cast parts to achieve tight dimensional tolerances, which cannot be achieved as-cast. Zetwerk also has the capability to heat treat the part to achieve the desired mechanical propeservicerties. Investment cast parts typically need to be put through various surface finishing processes such as pickling & passivation, electroplating, polishing, powder coating or ultrasonic cleaning, as dictated by the engineering specifications. Other services Zetwerk provides includes assembly work where we can provide the parts we produce put together in a sub-assembly and this service can include acquiring hardware or other components involved in the assembly.
Zetwerk also offers a wide range of in-house/third-party casting quality inspection and product testing services necessary to ascertain compliance to engineering specifications. These cover but are not limited to, chemical composition testing, tensile strength testing, hardness testing, impact testing, dye-penetrant testing, magnetic particle inspection and radiography inspection.
Zetwerk’s global sourcing solutions are practically unlimited in terms of casting alloys/materials, production capacities, part sizes and weights, secondary operations, surface finishes, assembly and services. How can we help you?