The Unicast Ceramic Molding Process offers the simplicity of sand casting while still offering the quality of precision casting. Inexpensive to use and operate, the Unicast Process can be employed in any shop with a minimum of special equipment. Using ordinary patterns of wood, metal, plaster, epoxy, STLs, etc., a ceramic slurry is poured which, when set, forms a highly refractory mold. Castings produced from these molds offer a close degree of tolerance combined with exceptional surface finish. There are virtually no alloy limitations and most of the standard ferrous or non-ferrous foundry alloys can be readily cast.

> Step 1:
A pattern is provided that is a representation of the cast part that is desired at the end of the process. This pattern can be made of virtually any material, with the most popular being wood, metal, plastic, plaster, epoxy, or the new favorite Stereo Lithography. Because the mold formation process is done at low temperatures, almost any material is suitable for pattern use.

> Step 2:
Pattern is placed in a mold box to prepare for slurry. The ceramic mold begins as a slurry that is poured over the pattern. This slurry is one of the key items that sets the Unicast Process apart from other ceramic molding processes. By using specialized mixing and selection techniques during the manufacturing of our ceramics, we are able to duplicate even the most intricate pattern features. Right down to the grain in leathers or finer!

> Step 4:
The pattern is removed (and now may be RE-USED to make another mold), and the mold is cured at relatively low temperatures to remove any moisture in the mold. (Mold shown inverted from this point on.)

> Step 5:
After all moisture is removed from the mold, the mold is fired at approximately 1800 to 2000°F. While this step is not always necessary, especially for lower melting metals, it is recommended, as this process fully converts the ceramic phase, thus increasing the already high refractory qualities of Unicast ceramic and minimizing the possibilities of mold/metal reaction. Once the user is familiar with the process, they are generally able to determine easily the necessity for this step.

.

> Step 6:
The mold may now be cast by following regular foundry routine. Because of the high refractory properties of a Unicast mold, the foundryman is left with the unique advantage of being able to cast at any temperature, thus giving wide metallurgical control in realizing the maximum physical characteristics of the intended alloy.

> Step 7:
Knockout. When the mold had cooled, it is ready to be broken open to reveal the finished part. With proper technique, the casting should be easily removed and there should be no chipping necessary.