<h1>Streamlined Finishing, Exceptional Results: The Signicast Advantage</h1><p>Partnering with Signicast for investment casting finishing offers a distinct advantage: a comprehensive suite of secondary operations housed under one roof. This streamlined approach not only guarantees the highest quality cast components but also translates to significant benefits for customers.</p><h3>Efficiency and Cost Savings</h3><p>By eliminating the need to outsource finishing, Signicast's integrated process minimises lead times and reduces overall production costs. Customers enjoy the convenience of a single point of contact and the assurance that their components are handled with expert care throughout the entire manufacturing journey.</p><h3>Uncompromising Quality</h3><p>From machining and plating to specialised treatments, Signicast's finishing capabilities are second to none. The company's commitment to quality is evident in its state-of-the-art equipment, rigorous in-cycle part checking, and a team of skilled professionals dedicated to delivering consistent, flawless results.</p><h3>Reduced Risk, Increased Confidence</h3><p>Signicast's in-house tool room ensures minimal downtime in the event of unforeseen maintenance issues, further safeguarding customer projects and ensuring on-time delivery. This level of control and responsiveness sets Signicast apart, providing customers with peace of mind and the confidence that their components are in expert hands.</p><h3>From Design to Delivery, One Trusted Partner</h3><p>Signicast's seamless integration of casting and finishing fosters better component design, faster product launches, and fewer errors. By choosing Signicast, customers gain a true one-stop shop for their investment casting needs, backed by a commitment to quality, efficiency, and exceptional customer service.</p>

Signicast_Resources_Articles.png

From design to delivery, experience the advantage of a single, trusted partner. 

Streamlined Finishing, Exceptional Results: The Signicast Advantage 

Signicast's in-house investment casting finishing offers a streamlined, high-quality, and cost-effective solution with reduced risk, ultimately benefiting customers throughout the entire manufacturing process.

Streamlined Finishing, Exceptional Results: The Signicast Advantage

<h1>Investment Casting vs Metal Injection Molding</h1><p>If you're looking to create high-quality metal components and can't decide between metal injection moulding (MIM) and investment casting, you aren't alone. Many businesses have trouble choosing the best metal manufacturing process, knowing it will ultimately affect their bottom-line profits.</p><h2>What is Metal Injection Molding?</h2><p>MIM is a unique hybrid technology combining the processes of powder metallurgy and plastic injection moulding. It starts when super-fine metal powders are mixed with a primary paraffin wax material and a secondary thermoplastic polymer. The final mixture is extruded and chopped into tiny pellets called "feedstock", which are then heated before being injected into a mould cavity under high pressure. It's a technique that delivers tighter net shape tolerances over high production runs, making it possible to produce extremely complex components with enhanced surface finishes.</p><h3>What is Investment Casting?</h3><p><a href="/investment-casting/process" target="_self">Investment casting</a>, also known as lost wax casting, begins with the creation of a wax injection die. Wax patterns are grouped and assembled onto a sprue to form a complete mould. The mould is then coated with layers of ceramic slurry and rapidly dried to harden the shell. Once dry, the mould is put into an autoclave to remove the wax from the mould. Molten metal is then added to the mould and allowed to cool. Finally, the shell is removed with high pressure water jets to reveal the final precision part.</p><h3>Material options – what process is best for certain alloys?</h3><p>Both investment casting and metal injection moulding produce strong, durable parts using a wide variety of alloys. For MIM, <a href="https://www.optimim.com/" target="_self">OptiMIM's</a> distinguishing factor is custom feedstock and the ability to specify metal particle size distribution and develop unique binder compositions. This makes the process fully customisable to deliver the end mechanical performance and properties your application requires. This also ensures that parts are more structurally sound, more reliable, and are less prone to embrittlement (cracking).</p><p>OptiMIM specialises in various ferrous and non-ferrous alloys including several stainless-steel grades, copper, and low alloy steel components which make up about 70% of our business. Specialty alloys, like Cobalt-Chromium (F-75) and other high alloy materials, are available as well.</p><p>Investment casting is such a versatile manufacturing solution in part because the <a href="/materials/metal-selector-tool" target="_self">material options are nearly endless</a>. At Signicast, we pour everything from 400-series stainless steel and plain carbon steel, to nickel and aluminium. This wide array of materials helps to deliver corrosion resistance, increased tensile strength, and ductility.  The availability of material options means that you don't necessarily have to sacrifice one element of a design in favour of lowering cost, and the versatility means we can more easily resolve traditional casting challenges in design, production, cost control, and delivery. </p><h3>Part Size and Quantity – What is achievable?</h3><p>MIM is ideal for producing large batches of small parts, roughly a half pound or smaller. In fact, most MIM parts fit in the palm of your hand down to a single grain of rice. Investment casting, on the other hand, is best suited for smaller lot sizes of large parts that are half a pound to 250 pounds, making it a cost saving alternative to machining from solid. When it comes to IC, think larger part and smaller lot size. Both processes scale very well, however MIM is the clear winner in terms of achieving high volumes - typically 10,000 parts or more - as this technology is a batch-driven process.</p><p><em>IC weight capability: 3g - 250 lbs</em></p><p><em>MIM weight capability: .05g - 35lbs</em></p><h3>Common Applications and Designs – What Industries Are Served?</h3><p>The MIM process is known for producing incredibly dense, precise parts with high strength and wear resistance, making it ideal for medical and dental manufacturers looking to meet strict regulatory requirements. In addition, scalability and heat resistance make MIM a great solution for automotive applications. Our ability to create parts from custom formulated alloys means we can deliver precisely the required performance characteristics.</p><p>Signicast's complex casting capabilities, <a href="/additional-capabilities/prototyping" target="_self">rapid prototyping</a> and secure supply chains make it the perfect solution for a <a href="/industries" target="_self">variety of industries</a>. Stainless steel is especially efficient for industries that require high strength and temperature resistance like aerospace and defence applications. Our specialised processes allow us to address specific needs – like thin-wall casting, for a lightweight, streamlined design in medical and dental instruments or part consolidation in locks, hardware, and recreational vehicles.</p><p>Interested in learning more about the capabilities of investment casting and metal injection moulding, download our free, on-demand webinar on IC vs. MIM by completing the form below. </p>

Compare investment casting and metal injection moulding to learn how they differ in tooling, tolerances, cost, and part complexity.

MIM vs Investment Casting | Process Comparison

See investment casting and metal injection moulding compared, outlining their benefits, material options, part sizes, and applications to help businesses choose the best method for metal component production. 

Investment Casting vs MIM: A complete guide

<h1>SOPHIA® Investment Casting: Applications in Aerospace, Defense, and Specialized Industries</h1><h2>Defining Sophia® for Aerospace, Defense, and Special Applications</h2><p>In the mission critical fields of aerospace, defence, and specialised applications, advanced innovation takes centre stage. SOPHIA®, an advanced investment casting process, is making waves in the industry. See why the impact of SOPHIA® investment casting manufacturing is crucial for components made in these sectors.</p><h3>What is SOPHIA®?</h3><p>SOPHIA® exemplifies precision and innovation in investment casting. Utilizing a controlled cooling process post-casting, SOPHIA optimises parameters for enhanced component geometry, resulting in a finer microstructure and superior mechanical properties. Developed in the late 1980s, the process focuses on achieving controlled and accelerated solidification.</p><p>Molten aluminium is poured into a hot shell in front of the SOPHIA® chamber at around 750 degrees Celsius. The mould is then transferred into the chamber for a computer-controlled descent into a cooling medium between 40 to 60 degrees Celsius, adjusting speed based on component geometry.</p><p>This method produces a finer microstructure, delivering higher strength compared to conventional casting. Implemented in only four global plants, including Soest, SOPHIA employs three times cooling to rapidly cool the mould, initiating solidification and further cooling the aluminium.</p><p>Post-casting, the mould goes into the SOPHIA chamber for a part-specific program tailored to volume and wall thickness, ensuring controlled solidification. Steps include initiating solidification at the lowest edge, descending at a defined speed, and stopping just below the upper edge to avoid overtaking the solidification front.</p><p>Compared to conventional casting, SOPHIA achieves a smaller dendrite arm spacing (DAS) and superior eutectic moulding, eliminating the need for additional melt modification. SOPHIA emerges as an advanced and efficient method in investment casting.</p><h2>Precision without Complications</h2><p>SOPHIA® excels in achieving close tolerances and excellent surface quality without the need for mould angles. Lightweight components, the ability to map undercuts, and near-net-shape characteristics contribute to intricate designs with improved fuel efficiency and enhanced overall performance.</p><h2>Material Freedom and Alloy Overview</h2><p>Offering freedom in material choices, SOPHIA® works seamlessly with high-performance aluminium alloys:</p><ul><li>A357 (AlSi7Mg0.6)</li></ul><ul><li>A356 (AlSi7Mg0.3)</li></ul><p>Characteristics such as minimum wall thickness (1.5-2 mm), excellent castability, design flexibility, good weldability, corrosion resistance, and pressure tightness make SOPHIA® an ideal choice, leading to higher mechanical properties compared to conventional casting processes.</p><h3>Enhanced Mechanical Properties and Reduced Wall Thickness Dependence</h3><p>The SOPHIA® process significantly reduces the dependence of strength values on wall thickness. This leads to improved mechanical properties, offering designers a distinct advantage over conventionally manufactured milled parts.</p><h3>Practical Applications in Aerospace</h3><p>SOPHIA® finds application in various aerospace components, including landing flap fittings, handles, joysticks, casting HP pumps, LGSCU housings, electronic boxes, and engine casings for turbofans. Its ability to realise complex geometries makes it invaluable in meeting the highest requirements in the&nbsp;aerospace sector.</p><h3>Mechanical Properties and Fatigue Life</h3><p>Comparisons between conventional and SOPHIA® investment castings reveal marked improvements in fatigue life. With unnotched test specimens, SOPHIA® castings show significant enhancements, providing a competitive edge in dynamic properties.</p><h3>Welding Capabilities</h3><p>In the qualification testing, SOPHIA® demonstrates consistent dynamic properties in in-process welding. The welded test bars, using the same chemistry as the parent material, exhibit identical dynamic properties compared to non-welded counterparts.</p><h3>Casting Factor and Process Controls</h3><p>With a casting factor of 1 according to CS 25.621 (EASA), SOPHIA® qualifies as a premium casting process. Strict process controls, including time and temperature mould adjustments, transfer times, metal temperature, spectral analysis, density index, and more, ensure a reliable and consistent casting process.</p><p><strong>For more information, check out our &nbsp;whitepaper on the SOPHIA® process. </strong></p>

See how the SOPHIA® investment casting process enhances precision, mechanical properties, and material flexibility for aerospace, defence, and specialised industries. 

Aluminum Castings for Aerospace & Defense

The SOPHIA® investment casting process revolutionises aerospace, defence, and specialised industries by delivering superior mechanical properties, precision, and material freedom, making it ideal for mission-critical components.

<h1>Kovar Spotlight</h1><p>Following the success of Invar 36, Signicast expands its offerings with Kovar, an iron-nickel-cobalt alloy. Kovar, sharing the "Invar Effect" with its predecessor, boasts low and linear thermal expansion below the Curie Point, then expands significantly above it. While Invar prioritises a minimal coefficient of thermal expansion (CTE) for temperature stability, Kovar's "co-variant" nature ensures its CTE closely aligns with borosilicate glasses and certain alumina ceramics.</p><h2>What are the Benefits and Applications of Kovar?</h2><p><a href="/materials/thermal-expansion-alloys" target="_self">Kovar's thermal expansion</a> rate is the key property that makes this super-alloy useful. Compared to other alloys, Kovar expands at a variable rate with increasing temperature with very little change in dimension. This makes Kovar a great fit for seals and glass-to-metal bonded assemblies with minimal locked-in pressure.</p><p>It is used in applications requiring a hermetic seal between the metal alloy and the glass or ceramic component. The metal to glass seal is created by performing an oxidising treatment to the parts after they have been annealed. The oxide layer is intermediary, bonding both to the glass and to the alloy substrate on which it was formed. The hermetic seal creates a bond free of the trouble and failures caused by dirt, dust, moisture, fungus or lack of pressure at high altitudes. Applications for this alloy include x-ray tubes, microwave tubes, and light bulb ends among many others.</p><h2>Physical and Mechanical Properties</h2><p>By varying the amounts of the major alloying elements, the CTE behaviour of these alloys can be tailored to match different ceramics and glasses.</p><p>Kovar's typical physical and mechanical and physical properties are as follows:</p><ul><li>Density: .302 lb/in3roperties are as follows:</li></ul><ul><li>Curie Temperature: 435 ºC</li></ul><ul><li>Melting Point: 1450 ºC</li></ul><ul><li>Specific Heat:</li></ul><ul><li>.105 cal/gm/ ºC at 0 ºC</li></ul><ul><li>.155 cal/gm/ ºC at 430 ºC</li></ul><ul><li>Heat of Fusion: 64 cal/gm</li></ul><ul><li>Thermal Conductivity: 17.3 W/m · K</li></ul><ul><li>Electrical Resistivity: 490 microhm/mm</li></ul><ul><li>Shear Modulus: 7.5 · 106</li></ul><ul><li>Modulus of Elasticity: 20 · 106</li></ul><ul><li>Ultimate Tensile Strength: 75,000 psi</li></ul><ul><li>Yield Strength: 50,000 psi</li></ul><ul><li>Elongation: 30%</li></ul><ul><li>Hardness (Rockwell B): 78</li></ul><h2>Investment Casting Manufacturer</h2><p>With world-leading experts, <a href="/additional-capabilities/prototyping" target="_self">rapid prototyping</a> and delivery, and the <a href="/locations" target="_self">most advanced investment casting facilities</a> in the world, Signicast is redefining how today's manufacturers create, refine, and deliver products. Whatever your situation, our expert engineering staff is ready to listen. With 30 <a href="/additional-capabilities/engineering" target="_self">in-house engineers</a>, we partner with you on every project to ensure your component is the highest quality possible.</p>

Explore Kovar alloy's low thermal expansion and sealing reliability, making it ideal for hermetic components in electronic assemblies.

Kovar Alloy Spotlight | Investment Casting Article

Kovar, a special alloy ideal for creating strong, airtight seals between metal and glass, is offered by Signicast, along with their expertise in crafting high-quality parts.

Streamlined Finishing, Exceptional Results: The Signicast Advantage

Streamlined Finishing, Exceptional Results: The Signicast Advantage

Efficiency and Cost Savings

Uncompromising Quality

Reduced Risk, Increased Confidence

From Design to Delivery, One Trusted Partner

Interested in starting your investment casting journey?