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<p>Experience product optimisation with our investment casting solutions, delivering added value through intricate designs, superior quality, and cost-effective production.</p>

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Product optimisation and added value

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Whether our customers face recurring challenges during product development or production issues that have proven difficult to solve elsewhere, we help companies streamline production processes, reduce material waste and optimise designs for manufacturability with our expertise.

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Enhanced engineering

Enhanced design for manufacture 

Using net-shape parts minimises additional processing steps, which not only saves time but also reduces labour and operational costs. 

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Reduce secondary operations 

Reduction of secondary operations 

Enhance the visual appeal and functional performance of the final product to improve corrosion resistance and longevity.

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Improved surface finish 

Offering complete kitting and tailored packaging solutions enhances the customer experience by simplifying assembly and reducing handling time. 

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Kitting and packaging 

Comprehensive kitting and packaging 

Discover the advantages of Signicast’s product optimisation solutions

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Design for manufacture is integrated from the outset of production to ensure that engineers can optimise part designs for efficiency, cost-effectiveness and manufacturability.

Design for manufacture 

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With investment casting, we can produce a single net-shape part that eliminates the need for multiple components, simplifying assembly and enhancing overall structural integrity.

Net-shape parts

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Using sub-assemblies with investment cast parts enables streamlined assembly processes and improved design flexibility.

Sub-assemblies

Our in-house machining capabilities optimise investment cast parts by ensuring precise dimensions and finishes, enhancing performance and reducing the need for external processing.

Machining 

NDT ensures structural integrity and reliability without compromising the component, increasing customer confidence and reducing the risk of failure.

Non-destructive testing 

Secure and efficient transport minimises the risk of damage and enhances overall presentation and readiness for use.

Packaging 

Investment cast parts are pre-assembled with necessary components, reducing assembly time and improving overall efficiency for our customers.

Kitting

Elevate your product, eliminate secondary operations 

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<p>An effective <a href="/additional-capabilities/prototyping" target="_self">investment casting prototype</a> should be more than a mere replica. It should be robust enough for strength testing, accurately represent the geometry of the final part, and validate the concept. A well-executed, functional prototype is the crucial first step in taking a project from the drawing board to full-scale production.</p><p>Signicast offers a range of prototyping technologies to meet specific project requirements, and our engineering specialists have extensive experience producing prototypes across <a href="/industries" target="_self">various industries and applications</a>.</p><h2>Prototyping options for effective testing</h2><p>To select the most suitable prototyping process, the physical properties and testing requirements of the end component must be determined. These requirements help narrow down the available options.</p><h3>Short-run, hard-tooled prototype</h3><p>When a prototyping process is required to produce numerous parts that precisely match the mechanical and physical properties, dimensions and tolerances of the final component, a short-run, hard-tooled prototype is the most effective choice. Although it involves an initial tooling cost, it produces prototypes at a lower per-piece price than processes using SLA or PMMA. If a project requires an exact prototype and rigorous yield strength testing, a hard-tool prototype is the optimal solution.</p><h3>3D-printed wax pattern</h3><p>For design validation, proof of concept, fill validation or replicating the mechanical properties of an investment cast component, 3D-printed wax patterns offer efficiency and rapid turnaround. These patterns are produced in-house within hours and immediately transformed into functional metal components. Recent technological advances have simplified the validation of surface finishes on these prototypes. The primary constraint of this process is component size, as printers can only handle parts approximately the size of a Rubik’s cube or smaller.</p><h3>SLA (stereolithography)</h3><p>SLA is similar to 3D-printed patterns but is used when the part size exceeds the capacity of our 3D printer, typically around the size of a sheet of paper (6 to 8 inches high). Like 3D-printed wax patterns, SLA prototypes mimic the mechanical properties of an investment cast component and are valuable for fit and design validation prototyping. The main distinction, aside from size, is that pattern removal in SLA is more manual.</p><h3>PMMA (polymethyl methacrylate)</h3><p>PMMA patterns resemble SLA patterns and can accommodate parts larger than those suitable for SLA. Like 3D wax patterns and SLA, PMMA is useful for refining surface finishes, fit and design validation, and replicating the mechanical properties of an investment cast component. PMMA also provides a good indication of the strength and repeatability of complex geometries.</p><h3>Machined from solid</h3><p>Machining from solid bar stock is generally a very rapid process, ideal for producing dimensionally accurate parts for fit assessment and proof of concept. To ensure speed, this process is best suited to low-volume aluminium alloy parts. Machining stainless steels and carbon steels takes longer, potentially increasing costs.</p><h3>DMLS (Direct Metal Laser Sintering)</h3><p>This process is suitable for prototypes with intricate geometries and precise features that cannot be produced with tooling. However, it is important to note that DMLS may not always match the mechanical properties of a true investment casting. While excellent for proof of concept and demonstrations, it may not withstand real-world testing.</p><h3>Which prototyping process is most effective for mass production?</h3><p>During a successful product launch, a combination of different processes may be used. The optimal prototyping process for any testing stage depends on the project scope and its proximity to product launch.</p><p>As the project approaches mass production, transitioning to a short-term hard-tooled investment casting run is recommended. This enables comprehensive testing and validation of all requirements for the final component.</p><h3>Maximising prototype value</h3><p>A crucial, yet often overlooked, aspect of prototyping is involving the supplier early in the design phase. Designing the prototype for <a href="/additional-capabilities/product-optimization-and-added-value" target="_self">optimal manufacturability</a> is ideal, and the most direct way to achieve this is by collaborating with design engineers experienced in investment casting. This proactive approach can prevent setbacks during prototyping, such as the need to redesign a part to ensure proper mould flow and solidification, castability or alloy compatibility.</p>

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Discover how investment casting connects prototype validation with full production, delivering consistent results, shorter lead times and smooth progress.

Prototyping for production scale | Signicast article

A range of prototyping methods is available for mass production, each with its own advantages and limitations. Selecting the right method depends on project requirements and early supplier collaboration for optimal results. 

Prototyping for mass production

<p>Between cumbersome welded-steel prototypes and several discouraging production runs, John Pizzuti experienced first-hand the expense of using other methods and suppliers to bring his game-changing football face masks to market.</p><p>He then turned to <a href="/additional-capabilities/engineering" target="_self">Signicast’s engineering expertise</a> to manufacture his innovative designs more cost-effectively – while protecting the players who wear them.</p><h3>Enhancing safety and style</h3><p>Introducing new uniforms, logos and design elements is a popular strategy for US football teams to strengthen their identities. Whether bold or subtle, these occasional redesigns can support fan merchandising, attract attention for recruitment, or raise awareness for sponsors and causes.</p><p>But they cannot compromise player safety.</p><p>Partly for this reason, the face mask, seemingly a front-and-centre opportunity for team expression, has been excluded from branding changes in professional and college leagues.</p><p>After all, the main role of a face mask is protection, so league rules and certification standards have discouraged modifications to its most basic design.</p><p>John Pizzuti wanted to give face masks a new look to match the evolution of football uniforms, while maintaining a focus on safety. And so, Zuti Facemasks was born.</p><h3>Unmatched design with investment casting</h3><p>“I built my first prototypes the same way they had been built for decades,” says Pizzuti. “By welding together quarter-inch, cold-rolled steel.”</p><p>When he was finished, he was not happy with the way they looked – and it had taken a month to build them. “There was no way I could make a profit,” he says.</p><p>Pizzuti sought advice from his mentor, a long-time automotive industry professional who also happens to be his mother. She suggested that he switch to <a href="/investment-casting" target="_self">investment casting</a>.</p><p>“A light bulb went on in my head,” he says. “Last I checked, you have unfettered.” This was ideal, as the innovative design of Zuti Facemasks allows teams to seamlessly integrate stylised elements into the grille, creating a potential platform for branding.</p><p><em>“With investment casting come geometric advantages that we could build into these face masks,”</em> Pizzuti says, “and that could help with energy distribution and, ultimately, safety.”</p><h3>Expertise-driven structure</h3><p>Initially, he found an investment casting supplier but encountered obstacles, as they faced non-fill and scrap issues, resulting in low percentages of viable parts.</p><p>That was when he was contacted by Lann Ellis of Signicast, who was intrigued by a Modern Casting article about Zuti Facemasks. “This project could be a disruptive innovation for leagues,” says Ellis. “I figured that, with our engineering resources, Signicast could drive Zuti into .”</p><p>The timing was right for Pizzuti. <strong>“</strong><em>Every time Lann called, he gave me a new value-added strategy that we could implement, whether it was a way to reduce costs or achieve economies of scale.</em><strong>”</strong> So, Zuti Facemasks made the <a href="/about-us/company-overview" target="_self">switch to Signicast</a>.</p><p>Behind the scenes, Signicast’s diverse engineering team – a project engineer, a metallurgist and a process engineer – could implement improvements during manufacturing. These enhancements included material modifications, fine-tuned temperatures or hold times, and other variables.</p><p>This expertise-driven structure was agile enough to allow Pizzuti to make changes quickly, says Ellis. It also meant they could deliver a higher-quality face mask.</p><h3>Innovation achieves superior safety standards</h3><p>Following the debut of the initial prototype from Signicast, Zuti Facemasks knew it had a winner.</p><p>“I could tell with the naked eye that the quality was much improved,” says Pizzuti. “But then I took it a step further and had it X-rayed.”</p><p>He notes that although the surface finish of an investment cast part can be beautiful, internal inclusions may still be present – a similar issue observed in the prototypes from his previous supplier.</p><p>“When we switched to Signicast, all of that went away. The voids and/or non-fill in the material, the grain structure – it was simply that much better. There was less shrinkage. <em>It was an overall better-quality part</em><strong>,”</strong> Pizzuti says.</p><p>Since Zuti Facemasks uses an innovative design and a manufacturing process atypical for the industry, the biggest test came from NOCSAE, the standards body for certifying athletic equipment to reduce injuries. As Pizzuti predicted, given the freedom to incorporate impact-dissipating geometries, his face masks passed.</p><p>This is good news for youth, high school and college football teams and leagues that need confidence that their equipment is safe.</p><p>And, equally appealing to teams that demand a more distinctive appearance on the field, Pizzuti says, “it simply looks much better.”</p>

Football helmet face mask with a surface finish

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Discover how switching from a multi-part welded assembly to a single casting saved time, simplified logistics and improved repeatability and consistency.

Welded steel to investment casting | Signicast case study

John Pizzuti, founder of Zuti Facemasks, partnered with Signicast to overcome manufacturing challenges and create innovative, safe and stylish football face masks using investment casting. 

From welded steel to an as-cast solution

<h1>Prototyping for production FAQs</h1><p>When designing and developing your components, <a href="/additional-capabilities/prototyping" target="_self">developing a prototype</a> is one of many critical steps towards a successful programme launch and efficient mass production.</p><h2>How do you choose the right prototyping method?</h2><p>While 3D printing is becoming increasingly popular, selecting a metal prototyping option requires careful consideration. It is essential to begin with the basics and assess the cost implications of various factors to achieve optimal long-term results.</p><p>The geometry, size and quantity of the final component are the primary factors influencing the choice of prototyping process because of their impact on cost. Specific features and properties may be better suited to one process than another. Additionally, it is necessary to determine whether the prototype will serve solely as proof of concept or whether a fully functional part is required for real-world testing.</p><p><strong>Rest assured, a team of </strong><a href="/additional-capabilities/engineering" target="_self"><strong>investment casting engineers</strong></a><strong> can help determine the ideal prototyping option for any project.</strong></p><h2>Prototyping stage for alloy selection</h2><p>The prototyping stage provides an excellent opportunity to test different material options. With&nbsp;investment casting, <a href="/materials/metal-selector-tool" target="_self">multiple material options</a> can be explored during prototyping. For example, 3D-printed patterns can be used instead of traditional wax patterns, allowing engineers to print multiple patterns and run them through different moulds with different alloys to identify the best alloy based on the component’s mechanical and physical properties.</p><h2>Lead time for tooling and fixtures</h2><p>With an in-house toolroom, tools and fixtures are built concurrently. The toolroom operates continuously, just like the foundries, ensuring there are no time gaps. As there is no reliance on external sources for tool manufacture, standard tooling lead times are three to five weeks.</p><h2>In-house production machining capabilities</h2><p>Both <a href="/investment-casting/machining" target="_self">in-house production machining</a> and machining for prototyping are available. A well-equipped machine shop houses three-, four- and five-axis machining centres with a wide range of capabilities.&nbsp;Plant tours&nbsp;are available for those interested in viewing the facilities firsthand.</p><h2>Differences between parts made with manual tooling and production tooling</h2><p>Generally, there are no significant differences. Manual tooling limits injection speed, so the main distinction lies in the injection rate. Fully production-ready tooling enables automated presses and robotic part removal associated with a full-scale investment casting production run. For higher-volume prototyping projects, a production tooling environment offers greater efficiency.</p><h2>Available non-destructive testing (NDT) processes for investment cast prototypes</h2><p>A variety of NDT procedures are available, including fluorescent penetrant inspection (FPI), magnetic particle inspection, X-ray, test bars, dimensional scanning and coordinate measurement (CMM). Regardless of the testing requirements, whether during printing or post-production, the resources and capabilities are in place to deliver functional prototypes.</p><h2>Fully functional metal prototypes</h2><p>Finding a supplier capable of consistently delivering effective prototypes is crucial. With investment cast prototyping, there is no need to compromise quality for time or cost.</p>

Prototyping lab for the Signicast engineering team

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Explore answers to common questions about prototyping cast parts, including tolerances, lead times and transition to production tooling in investment casting.

Prototyping FAQs for investment casting | Signicast article

See how a part’s fit, form and function can determine whether it is a suitable candidate for investment casting, a process offering superior design flexibility and cost savings compared with traditional methods.

Prototyping for production FAQs

Expand your knowledge of Signicast product optimisation and added value 

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Product optimisation and added value

Elevate your product, eliminate secondary operations

Design for manufacture

Net-shape parts

Sub-assemblies

Machining

Non-destructive testing

Packaging

Kitting

Beyond the basics

Expand your knowledge of Signicast product optimisation and added value

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