Unicast Ceramic Molding Process
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The Unicast Ceramic Molding Process is a newer casting process that is more efficient at creating precision molds than previous methods. It can produce highly detailed parts at a cost lower than traditional high-precision methods. Existing casting facilities can be converted to use the Unicast process with little effort. The unique part of Unicast Ceramic Molding is the ceramic slurry used to make the mold. It is specially chosen and combined to form a mold with highly intricate patterns, even being able to replicate ultra fine details and textures. The slurry also cures so well it has virtually no alloy limitations and can handle most standard ferrous and non-ferrous foundry alloys. The Unicast process has the simplicity of sand casting but with all the benefits that come with using the unique ceramic slurry.
[edit] Process
To begin the Unicast Ceramic Molding Process on a solid part, place a pattern of the part on a workstation. The pattern can be made of wood, plaster, epoxy, metal, or any standard pattern material. The low temperatures used in this process allow for a wide range of usable materials. The pattern should be highly accurate to the desired part, as dimensional tolerances are very low with this process.
After pattern is placed and secured, the ceramic slurry is poured into place. It is held in by the mold box the pattern rests in. After pouring is complete, the slurry is allowed to dry and harden. The pattern is now removed and used again to begin another mold. Depending on the needs of the part to be molded, the ceramic can be treated by exposing it to 2000°F. After treatment, the ceramic mold works as any other mold in a foundry setting and can be used to make the part. The process is simple and after the part is cast, the mold should break apart easily without the need for chipping.
[edit] Typical Uses
The Unicast Ceramic Molding Process can make any part that sand casting can, with minimal difficulty. The benefit of the ceramic characteristic is the level of detail it can achieve. More difficult parts can be made easily using the Unicast process. It can handle very complex parts, yet is as easy to do as sand casting. There is much less skill needed than traditional complex part manufacturing processes.
