Prototype Aluminum Casting Methods

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Prototype Aluminum Casting Methods

Our prototypes are made either by the plaster or air-set sand process. The type of casting dictates the method that we use, unless specified by our customer.

The plaster process is used when fine detail and finish are essential. Thin wall castings can also be cast with this method. Walls down to .060" can be cast.

Rubber patterns can be used when making plaster molds. When using rubber patterns, minimal or no draft is needed, facilitating a cast to print part. Cast to size castings help to cut down machining costs. Also, with rubber tooling, minimal parting compound is required thus insuring more detail.

With plaster molds, porosity can be a problem. We've nearly eliminated porosity using a rotary degassing unit using a special blend of gasses.

Plaster molds drying in one of our large capacity ovens. Molds must be fully dried before metal is poured into them.

Please click on any photo on this page for a more detailed view.

One-cylinder air compressor engine block.
Approximate weight: 7 lbs.
356 Aluminum. Plaster method.

Two views of a 2 liter intake manifold.
Approximate weight: 12 lbs.
356 Aluminum. Plaster method.

Tecumseh Air Compressor Motor Block Mold

Mold for Tecumseh air compressor motor blocks.

Tecumseh air compressor motor block castings.

Rubber pattern for an oil filter adapter unit.

Valve Covers.
Approximate weight: 7 lbs.
Dimensions: 6" x 18" x 4".
356 Aluminum. Plaster method.

Plaster mold castings are noted for their reproduction of fine surface detail. Pictured here are aluminum dipping mandrels for the rubber industry along with a Nerf ball mold.

Prototype Throttle Bodies.
Approximate weight: 1 lb.
356 Aluminum. Plaster method.

Air-set sand is used when thick chunky castings are made. The sand cools the metal faster, helping to eliminate shrinkage & porosity. Extremely thick castings can be cast this way.

We also have a green sand department for producing long running jobs. We work very closely with several pattern shops and can take your job from print through production.

Rear Differential Housings.
Air-set sand process. Approximate weight: 10 lbs. 356 Aluminum.

Allison Transmission Housing
Approximate weight: 50 lbs.
Porosity free. Fully machined.
Air-set sand process. 356 Aluminum.

Feel free to give us a call at out toll Toll Free No: (877) 499-2278 = (877) 499-CAST) for casting, aluminum, prototype, bronze, tooling, foundry, aluminum foundry, match plate, prototype aluminum casting, castings, aluminum tooling, match plate, alloy, alloys, alunimum, aluminun, brass, zinc, plaster, air set sand, mold, molds, metal castings, cast iron, permanent mold and tooling SERVICE.