What is lost wax casting?

1. Model Creation

The initial step in the lost wax casting process involves crafting a model of the component that needs to be reproduced. This model may be manually sculpted from wax, machined, or designed using computer-aided design (CAD) technology, ready to be scaled to the desired size. In this phase, sprues are incorporated to facilitate the escape of molten wax and to ensure proper filling of the cavity. It is important to note that each wax model is a one-time use. The design takes into account thermal shrinkage that occurs during the cooling process.

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2. Mold Construction

Following the model creation, the wax pattern is enveloped in a refractory ceramic material along with a ceramic slurry to form a robust shell around it. This shell undergoes a drying and hardening phase, after which the embedded wax is melted away in a kiln, resulting in a hollow cavity mirroring the original model. Due to the wax's non-reusability, this process earned the name 'lost wax casting.'

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3. Casting and Unveiling the Final Product

Prior to the actual casting, the mold undergoes reheating in a kiln to align its temperature with that of the molten metal. At this point, the molten metal is poured into the established cavity either through gravity or under vacuum pressure. Once the metal solidifies and cools down, it reflects the shape of the initial wax model. The resulting cast part becomes accessible by breaking apart the ceramic shell and trimming off the sprues.

4. Post-Processing Steps

Once the metallic component is revealed, several finishing processes may be applied, including sandblasting or grinding. To ensure that the final product meets specific characteristics, further machining might be required. If the product comprises multiple elements or necessitates additional attributes, welding or assembly might be conducted to integrate the parts seamlessly.

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