Pattern Making

Sanding casting is a time-tested, reliable method to produce large metal parts. As we move towards to digitize production,we have adopted 3D printing as part of our upgraded process.

Traditional sand casting requires a 2D drawing to be translated and fabricated by a highly skilled pattern maker, which can be slow and expensive. Alternatively, some manufacturers turn to CNC milling to produce their patterns, but this method can not create certain complex geometries and wastes a lot of material, time and money. 3D printing, and specifically large-scale EMRAK machines, can speed up production while reducing costs and breaking free of traditional production chains.

Using 3D printers have modernize our foundry and simplified the first phases of sand casting, particularly when producing complex propeller patterns. The first step is to design and print the pattern. For reverse engineering projects, it is possible to scan existing propeller to create the 3D model. If the object to be casted is larger than the volume of the printer. Then it can be printed in multiple parts and assembled. If needed, the 3D printed pattern can be post-processed with a variety of methods.

The remaining steps are standard sanding casting processes. The printed pattern is then packed with sand and removed from the mold. Molten metal is poured into the mold cavity and the final cast part is then machined grided and polished.