The Unicast Process™
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 3:
The slurry mixture is poured over the pattern and allowed to
solidify.
> 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.
