The investment casting process produces near-net-shape metal components with exceptional surface finish, fine detail, and dimensional accuracy—minimizing or even eliminating the need for secondary machining and significantly reducing costs. Additionally, incorporating additive manufacturing in the investment castings process allows the production of complex, thin-walled components with added flexibility in lightweight design. Plus, investment casting can be used to quickly supply components for the Low-Rate Initial Production (LRIP) phase which can then be transitioned into Full-Rate Production (FRP) with hard tooling.
Today, the investment casting process is widely used across industries such as aerospace, defense, automotive, medical, and energy, where precision, durability, and weight reduction are critical. Its ability to produce lightweight, complex, and high-strength components makes investment casting an increasingly preferred choice for manufacturers seeking innovation and efficiency.
A common myth has persisted: that for just a few parts, it is more economical to machine them from solid billet, or “hog them out,” rather than use investment casting. In reality, machining from billet is often more expensive and less efficient. When you hog out a part, you’re typically removing 50% to 90% of the material. That means you’re paying for metal that ends up as scrap. Add to that the hours spent on a CNC machine, the wear on expensive tooling, and the cost of labor—and suddenly, what seemed like a quick solution becomes costly.
The extremely tight investment casting tolerances also impact the precision and functionality of the investment cast parts by:
Many metal cast parts are components of larger assemblies.
If tolerances are too loose, parts may not fit together correctly, causing misalignment, leakage, or mechanical failure.
Precise tolerances ensure uniform material distribution, reducing stress concentrations that could lead to cracks, warping, or premature failure.
Industries like aerospace, automotive, and medical devices require high precision for optimal performance and safety.
Even slight deviations can lead to inefficiencies, increased wear, or failure in critical applications.
At Barron, we take pride in our state-of-the-art investment casting process, which reliably produces complex, high-precision components with an excellent as-cast surface finish. Here is how we do it.
The first step in investment casting is to develop the pattern. This is generally done by injecting wax into a metal tool or “die” to form a single piece. For rapid prototypes and complex production pieces Barron uses additive manufacturing technology to 3D print patterns.
After the patterns are created, they are then connected to a central gating system, also known as the sprue, to form the tree assembly. Rather than create parts one at a time, the sprue works as a mounting surface to create several patterns into one mold.
Once the pattern tree is assembled, it’s then dipped into a ceramic slurry and covered with coarse material. Barron’s six-axis dipping robot ensures consistency and uniformity of shell production in intricate and complex parts. When the slurry dries, it produces a ceramic shell around the tree or individual pattern. This process is repeated until the mold shell reaches its desired thickness and hardens completely.
After the shell is built, a flash fire oven is used to remove the wax or 3D printed pattern prior to the metal being poured into the mold. The heat from the oven melts away the leftover pattern and treats the shell so it’s ready to cast. Additionally, the scorching oven temperature increases the stability and overall strength of the ceramic mold.
Once the mold has been cleaned, it is then preheated to a specific temperature to improve fluidity and surface finish. When heated accordingly, the molten alloy is then poured into the mold cavity. The mold is then given time to cool.
After removing the parts from the sprue and taking out the gates, the surface of the part needs to be finished. This can be done in a variety of ways. At Barron Industries, we offer the following finishing services:
Design Flexibility
Surface Finish
Complexity
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We make it simple to source custom casting and assemblies. Contact Barron Industries today to learn how we will put a century of experience to work for you.
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