- Metals (overview)
- Plastics (overview)
- CAD Design
- Rapid Prototyping
& Rapid Tooling
- CNC Machining
- Finishing & Assembly
- Rubber Plaster Molding
- Precision Airset Sand Casting
- Graphite Mold Die Casting
- One-Shot Casting
- Reaction Injection Molding (RIM)
- Rapid Injection Molding
- Design for Manufacturability (DFM)
Technical Information: One-Shot Casting Process
Download the PDF version of this document
How, When & Why to Use It:
- To produce precision and premium quality aluminum, zinc and magnesium castings.
- Prototyping - to assist engineering in debugging design before committing to any tooling.
- For very low-volume applications, including field replacements and lost tooling.
- For parts with complex or unusual shapes.
- For castings with thin walls or where weight is critical.
- To simulate die castings for prototype evaluation.
- To enable multiple design iterations (no tooling to change).
- To reduce "time to market" on new programs and evaluate market potential.
- To reduce time for machining and secondary operations.
- To assist and reduce time for U.L. approval.
Design & Technical Information
No limitation but best range within 2 in. cube to 18 in. cube.
Considerable design freedom for unusual and complex shapes, including deep undercuts.
Thin wall: 0.030 in. - 0.060"
Average: 0.080 in. - 0.120 in.
Thick wall: 0.180 in. - 0.500 in.
0 - 2 in.: +/- 0.005 in.
>2 in.: +/- 0.005 in. plus +/- 0.0015 in. for each inch over 2
The process is limited to non-ferrous metals with pouring temperatures below 2,000 °F - this includes aluminum, zinc and magnesium casting alloys and some copper based alloys.
Economical to cast small diameter holes to eliminate secondary drilling operations.
Aluminum, zinc, magnesium and some copper-based casting alloys to the commercial and military specifications. See separate technical sheet.
No draft is needed.
Corner radii and fillets as required. 0.025 in. minimum recommended.
Tensile - Yield - Elongation - as per the appropriate commercial and military specifications. See separate technical sheet.
1 - 2 weeks.
- Castings for telecommunications, business machines, medical equipment, computers, automotive, aerospace, electronics and robotics.