Metal casting is a long-standing metalworking technique in which melting and cooling of molten metal forms inside a mold, forming metal components. Despite its long-standing roots, it is an extremely sought-after method used by companies that want to make metal parts.
High pressure casting is a process wherein molten metal is forced, under pressure, into a sealed mold cavity.
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Since the advent of metal casting, the methods have evolved and varied. Its core techniques, however, have remained constant.
Here is a general step-by-step process for metal casting:
Step 1: Patternmaking
In order to begin the metal casting process, a manufacturer first must develop a representation of the desired pattern. This pattern is essential in designing the mold used for the cast.
It is traditionally made from wood, foam, plastic, or wax and ensures that the mold accurately produces the finished metal part. Today, 3D printing is also a common method to produce patterns, which allows designers to create accurate patterns directly from digital CAD software tools.
Step 2: Moldmaking
The next step is creating a casting mold, which can be either reusable (non-expendable) or non-reusable (expendable).
Non-reusable molds are usually made out of sand, plaster, wax, or by 3D printing, and just as the name suggests, they get destroyed in the casting process. Reusable molds are made out of metal and other durable materials and can be reused for multiple casting cycles.