Cast-to-Size Tooling

The Unicast process allows for the ability to create cast-to-size tooling suitable for use with plastic injection molding, low pressure die-casting, permanent molding, and the rubber and tire mold industries.  The precision and surface finish capabilities of the process allows for a tool to be cast that requires only polishing of the cavities prior to use.  This is not Near-Net-Shape where the tool is cast close to the finished dimensions and is machined the rest of the way.  This is Cast-to-Size where the tool cavity is cast directly to the finished dimensions.

Here are some applications where the process is being used.

Tire Molds

These tire molds allow for drastically reduced finishing operations after casting.  The cavity is as cast and only requires machining to fit all the sections together in the final tool.

Injection Molds

Deep cavity molds are especially beneficial when compared to machining due to the large amount of material needed to be machined out.

Permanent Molds

Permanent molding is a process where a lower melting point metal is cast directly into a higher melting alloy mold.  This process creates very good surface finishes and is ideal for higher volumes.  However, these types of molds also experience high wear rates and are frequently repaired and made new during the life cycle of the production part.  With a cast to size mold, it is less expensive usually to re-cast the entire mold than the cost of repairing it.  When molds are replaced frequently, cast tooling is ideal.

Die Casting

Die casting is similar to permanent molding in that metal is being cast into another metal mold.  However, volumes are usually considerably higher.  In these cases, we recommend an insert system be used where the actual die cavity is cast-to-size and used in a larger assembly capable of being fitted into the die casting machine.  Dies like the above die can be cast in alloys like Beryllium Copper which have exceptional thermal and wear characteristics - but are difficult to machine.

Shoe Molds

Shoe molds are commonly cast in aluminum with plaster molds.  while this process does create a mold that is suitable for molding of the shoe soles, it is limited in that the aluminum does not wear well.  With Unicast, the shoe mold is not limited to aluminum, but can be in iron, steel, and virtually any other higher melting alloy.

Rubber Molds

Automotive applications are particularly good candidates for precision cast tooling as speed to production is critical and the molds used in the automotive industry frequently employ textured surfaces to mimic leathers and grains.  With a Unicast mold, these textures are cast directly into the surface.  No acid etching or machining is required to obtain these surfaces.

Unicast has the experience and the know-how to help you get started.  Contact us for more information on cast-to-size tooling applications and see how easily you could be on your way to adding precision cast tools to your portfolio.

Interested in the process, but not in taking it on yourself?  If you demand precision in your castings, we can help direct you to a Unicast licensed facility in your area that is ideally suited to your type of work.  To request additional information, click here and select "Foundry References"