At FUNDIMAZZA, we perform investment casting—also known as precision casting—utilizing our own state-of-the-art, in-house tooling facility. This integration enables us to manufacture molds with greater precision, faster turnaround times, and lower final costs.

FAST PRODUCTION, WITH PRECISION AND EXCELLENCE!

The investment casting process, also known as lost-wax casting or precision casting, is an ancient, complex, and distinct foundry process used to manufacture metal components with the ability to utilize various alloys throughout the production. Components produced through this method are characterized by their intricate details, dimensional accuracy, and fine surface finish, which often eliminates the need for subsequent machining operations.

Today, investment casting has been adopted on a large scale by diverse industrial sectors, offering outstanding advantages. Compared to conventional casting, the primary benefit of this process — beyond drastically reducing the need for machining and enhancing the product’s surface finish — is ensuring the technical and structural integrity of the metal component.

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The precision casting process begins with a wax pattern, obtained through an injection molding process, which is coated with ceramic materials consisting of solid particles and refractory slurry in progressive grain sizes. This forms a mold that, once the wax is removed from its interior, becomes a hollow shell used to receive the molten metal. For every steel component, a corresponding wax pattern is required. This is achieved using injection molds and semi-automatic injection machines. Once injected, the wax patterns undergo a manual deburring process and are then welded by hand into a 'tree' assembly to ensure both technical viability and an economical layout.

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The empty ceramic shells ('casings') are preheated in a calcination furnace. This heating process provides the ceramic shell with the necessary stability to withstand the pressure of the molten steel later on. The glowing ceramic shells are removed from the calcination furnace using mechanical devices and repositioned on a sand bed, where they are immediately poured with the pre-specified steel, iron, or non-ferrous alloys.

This method guarantees that the investment casting process delivers exceptional dimensional accuracy and a superior surface finish. After pouring, the metal-filled ceramic trees are cooled at room temperature, causing part of the ceramic shell to break away from the formed steel parts. Any remaining ceramic residue is completely removed using pneumatic hammers and stainless steel shot blasting equipment.

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After its solidification, the metal—now a fully formed component—is removed from the ceramic mold, proceeding to the finishing stage and a rigorous final inspection to verify full compliance with customer specifications. Driven by superior efficiency and accelerated development cycles, the precision casting market continues to expand globally. Industry projections estimate that, over the coming years, more than 60% of companies not currently utilizing this manufacturing process will adopt it for their new projects.

If you still have questions about the precision casting process, explore these expert insights from FUNDIMAZZA: