Investment Casting Process

Barron’s Superior Casting Solution

Investment casting, or precision casting, is a process through which a mold is created around a pattern that is then melted out of the mold and replaced with molten metal. It is commonly used to produce high-strength and lightweight metal components with strict tolerance requirements.

Additionally, incorporating additive manufacturing in the investment casting process allows the production of complex, thin-walled components with added flexibility in design and materials.

What Is Investment Casting?

Also known as precision casting or lost wax casting. This process dates back more than 5,000 years and was used for making small pieces over the centuries. Today, investment casting is being seen as the future by many industries seeking lightweight and complex components.

Within the Investment casting foundry, It all begins with the production of a model or pattern which is created in the shape of the desired part. Read more about our investment casting process below.

Hot metal being poured into a cast

Quality Methods, Quality Casting

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.

Investment casting step 1

Create the Pattern

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.

Investment casting step 2

Cluster the 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.

Investment casting step 3

Build the Shell

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.

Investment casting step 4


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.

Investment casting step 5

Pour the Metal

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.

Investment casting step 6

Complete the Process

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:

  • Vibratory/media
  • Belting or hand grinding
  • Heat treating
  • Machining
  • Non-destructive testing
  • Polishing
  • Surface coating/painting
Investment casting

Benefits of Investment Casting

  • Design Flexibility: Many different alloys, including tool steel, stainless steel, carbon steel, aluminum, and low-alloy steel, can be used in the process.
  • Exceptional Surface finish and dimensional accuracy reduces the need for secondary finishing and machining, while also decreasing waste and lead-times.
  • Higher Complexity and Efficiency : Additive manufacturing is incorporated into the investment casting process by the 3D-printing of patterns which provides design complexity not achievable with traditional tooling methods. It can also eliminate the cost of tooling and machining while allowing faster delivery.
  • Environmentally friendly: The investment casting process includes recycling (of metals and wax) and it does not produce any toxic substances.
Design Flexibility
Surface Finish

Frequently Asked Questions

Find answers to the most commonly asked questions.

Most of our clients require a quote to be returned within ten days. However, for rapid prototype services, we can turn quotes around in as little as 24 hours

Barron pours more than 200 different ferrous and non-ferrous alloys including:

  • Carbon and Low Alloy Steels
  • Stainless Steels
  • Tool Steels
  • Aluminum Alloys
  • Nickel and Cobalt Alloy Castings
  • Gray Iron


Precision investment casting offers unlimited design freedom. It allows you to combine multiple manufacturing processes into one and offers a near net shape product. It also offers excellent dimensional stability, surface finish, thin sections and remarkably fine detail. Additional benefits include shorter lead-time and lower overall cost

Our team at Barron Industries reduces the possibility of defects by developing high-quality mold designs using our advanced casting simulaton software. Additionally, every component we produce is thoroughly tested using our NADCAP-certified non-destructive testing system.

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Superior Investment Casting Solutions

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