Lost-wax casting
Lost-wax casting is a process of producing sharp and detailed castings from3D models, designs, drawings and molds. This process is also known as investment casting, or cire perdue. It is an ancient technique that started in Egypt and Mesopotamia around 3800 BC.
The process begins with the creation of a prototype that is made out of wax. The prototype is usually sculpted or made on a computerized milling machine. It is then coated with a thin layer of rubber or plastic to protect and keep the details of the prototype while being casted.
The next step involves dipping the prototype in a ceramic material (Investment). This ceramic material will later become the shell of the casting. As it dries, the solidified investment will be strong enough to remain intact during the melting process due to its high heat-resistant properties.
After the investment is completely dried, the prototype is melted away from the ceramic shell. The edges are then cleaned and finished. This process is often done by hand with acetone and a bright light to better detail the casting.
To complete the casting, the ceramic shell is placed in a container that can withstand extreme temperatures. This container is filled with molten metal such as bronze, brass, aluminum or even steel. Once the metal has reached a high enough temperature, it is poured into the container and allowed to cool. In a few minutes, the shell will begin to breakdown and a precise, detailed casting will be revealed.
Lost-wax casting is a very precise and delicate process that has been used in the jewelry industry for centuries, to produce precise and intricate artwork. Jewelry that is cast in this process can be as detailed or as intricate as the designer wishes. This process allows for small intricate details to be achieved, along with strong and precise castings that can withstand high-pressure applications in products such as propellers and impellers.
Lost-wax casting can be used to produce small or large quantities of parts, from the most intricate and detailed designs. This process takes a lot of time and skill to master; however, once mastered, it is an investment in time and cost that will pay off for many years in producing precise and intricate designs for a fraction of the cost of machining processes.
