What is Plaster Mold Casting?

Step 1: Master Pattern Preparation

A precision master pattern is created based on customer drawings or CAD data, using SLA 3D printing, CNC machining or manual crafting. The pattern is engineered with allowances for metal shrinkage, mold taper and machining stock as required. We can also reproduce or modify customer-provided models upon request.

Step 2: Tooling & Pattern Fabrication

Master negatives are produced from the original pattern, followed by core plugs, resin upper and lower mold patterns, and core boxes. Gating systems, runners and flasks are integrated according to product requirements. Multiple sets of production tooling can be duplicated from the master negative mold.

Step 3: Plaster Mold Manufacturing

Liquid plaster slurry is poured over the resin patterns and into core boxes. After solidification, the plaster molds and cores are demolded and thoroughly baked to eliminate internal moisture.

Step 4: Metal Pouring & Demolding

The molten metal is degassed and spectroscopically tested to verify chemical composition before pouring. Qualified molten alloy is poured into the assembled plaster mold. After cooling, plaster residue is removed via mechanical knockout and high-pressure water jet cleaning, followed by removal of gates and risers.

Step 5: Inspection & Secondary Operations

Raw castings are inspected and serialized. Additional treatments such as heat treatment, X-ray testing and penetrant inspection are performed per customer standards. After final inspection, parts proceed to CNC machining, surface finishing including chemical film and chromate conversion coating, assembly, or form-in-place gasketing.