| Foam Mold Creation is fast and inexpensive with Criteria Systems
For larger scale objects, using foam for mold production at Criteria Systems is the fastest and most cost effective way to fabricate large tooling for limited production, either by using prototype models as patterns for a mold or by machining molds and cores directly from digital data. Whenever low tooling cost is needed, rapid prototype tooling with Criteria Systems is the answer.
Our foam carving and cutting system is ideal for those who work with architectural moldings, fibreglass production or concrete molds. Criteria Systems' foam cutting equipment can create intricate molds for precast concrete and GFRC using an innovative mold making process. Bringing superbly detailed design elements into concrete molds is possible with our automated sculpting capabilities. If architectural foam is your game, the our system can also cut beautiful architectural moldings - without the time and limitations of conventional sculpting or carving processes.
Using the Lost Foam Casting Process with Criteria Systems
The lost foam process is an ideal techinique to employ Criteria Systems Foam Prototyping technology.
First, a pattern is made from polystyrene foam, which can be done many different ways. For small volume runs the pattern can be hand cut or machined from a solid block of foam; if the geometry is simple enough it can even be cut using a hot-wire foam cutter.
Once the pattern is made pre-made pouring basins, runners, and risers can be hot glued to form the final pattern.
Criteria Systems can assist with the steps above. Following that, the casting process can be used.
Typically, the foam cluster is coated with ceramic investment, also known as the refractory coating, via dipping, brushing, spraying or flow coating. This coating creates a barrier between the smooth foam surface and the coarse sand surface. Secondly it controls permeability, which allows the gas created by the vaporized foam pattern to escape through the coating and into the sand. Controlling permeability is a crucial step to avoid sand erosion. Finally, it forms a barrier so that molten metal does not penetrate or cause sand erosion during pouring. After the coating dries, the cluster is placed into a flask and backed up with un-bonded sand. The sand is then compacted using a vibration table. Once compacted, the mold is ready to be poured. Automatic pouring is commonly used in LFC, as the pouring process is significantly more critical than in conventional foundry practice.
Did You Know?
Public recognition of the benefits of LFC was made by General Motors in the mid 1980s when it announced its new car line, Saturn, would utilize LFC for production of all engine blocks, cylinder heads, crankshafts, differential carriers, and transmission cases.
Contact us today to see how Criteria Systems can assist you with your mold making needs. |
