Resource Background

Ready to learn more? Explore our investment casting resources.

Resources

Signicast - Resources - L1

<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>

Signicast_Resources_Articles.png

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>Top 5 Things to Consider When Choosing an Investment Casting Company</h1><p>If you have ever worked with an investment casting company or visited their plant, you know how manually intense the process is—and it takes a lot longer than other casting methods. When searching for an investment casting company, there is no need to settle for traditional or ordinary. Here are the top five things to consider when searching for the best investment casting company.</p><h3>Quality &amp; Repeatability</h3><p>Investment casting is considered a net-shape or near net shape process and it can be done consistently with the right tools. We believe the key to great quality starts with early supplier involvement during the formative stage of product design. With over 30 engineers on staff, our technical and CAD capabilities are available to help you improve the way your existing component is produced—even if it was previously manufactured by another casting process.</p><p>We start with high-quality wax injection tooling and we create a manufacturing process that never stops. Our tool building process helps to reduce project time and aids in building more complex tools to create high-quality, complex parts with the tightest tolerances. Tool building process that is unparalleled in capability and speed. Everything is based on speed getting that tool finished. Additionally, we utilise simulation software to simulate solidification during the casting process resulting in significant time savings by eliminating multiple trials—thus achieving a high-quality repeatable process, the first time.</p><h3>Speed &amp; Delivery</h3><p>When you think of investment casting, we know most people are concerned with speed. In fact, some people would say that investment casting is one of the most frustrating casting processes because it is typically very slow. At Signicast, we have eliminated the word slow from all aspects of our business. We don't batch projects like other investment casting companies, we connect all the dots so each project runs as one complete operation—from tooling to finishing, robots move parts one from step to the next in a continuous flow. Other investment casting companies complete each process independently of each other—often leaving your parts sitting at one cell for weeks at a time—while Signicast does it all in one consecutive process. Doing so helps drastically reduce defects and potential part failure.</p><p>Speed is so critical especially if you are getting defective parts. You wait a long time and then get shitty parts. Combining the speed and the quality is the kicker. If you ship a part on-time but it's defective is it really on time? Quality before speed—but it just so happens we get everything done just as fast.</p><p>If you visit our Hartford, Wisconsin facility you will see a completely automated manufacturing system incorporating robotics, eliminating material handling to deliver your job faster and better than any other investment caster.</p><p>With true just-in-time delivery, you do not have to keep heavy inventory to cater to market fluctuations. Our average throughput for new product launch once we get the purchase order to build the tool, inject the parts, send samples, get approval and run the project, is less than 8 weeks. That is less than the average investment casting company takes to run a project for a current customer. </p><h3>Lowest Total Cost</h3><p>While many of today's casting companies promise the cheapest part price, Signicast strives to offer the lowest total cost which includes getting your product to market faster while still producing a high-quality cast part. We operate with a first to market mentality meaning our customers provide their production schedules and Signicast develops a delivery program to accommodate their workflow. Our continuous flow manufacturing process enables us to reduce cost due to less labour which in turns helps us create the lowest total cost for our customers.</p><p>The extreme flexibility of the Signicast investment casting facility is the reason why we are a true just-in-time manufacturer. Signicast is ready and equipped to handle radical shifts in output when you are faced with unexpected spikes in demand for your product. <strong> </strong></p>

Five factors to consider when choosing an investment casting company, including quality, speed, delivery, and cost efficiency, to ensure you partner with a reliable manufacturer. 

Top 5 Things to Consider When Choosing an Investment Casting Company 

The top five critical factors to consider when selecting an investment casting company, including quality, speed, delivery, and cost efficiency, emphasising Signicast's advanced automation, just-in-time delivery, and commitment to producing high-quality parts quickly and reliably. 

Top 5 Things to Consider When Choosing an Investment Casting Company

<h1>Investment Casting Material Options</h1><p>Access this free online seminar to discuss material options. From corrosion resistance to strength and ductility, learn more about alloy options and how they may fit into your next project.</p><p>Fill out the form below to receive the slides and video recording:</p>

Signicast_Resources_Webinars 2.png

Learn about material options for investment casting, including corrosion resistance, strength, ductility, and various alloys, in this free online seminar. 

Investment Casting Material Options 

This free online seminar explores material options for investment casting, covering corrosion resistance, strength, ductility, and various alloys, helping attendees choose the right materials for their projects. 

Investment Casting Material Options

<h1>How to Decide if Investment Casting is Right for You</h1><p></p><p>Is there an existing part currently being machined to achieve a specific geometry? There's a good chance that better results could be achieved with investment casting.</p><p></p><p>For anyone involved in precision components, the manufacturing process you select can have a significant impact on the final result you'll achieve. It's why so many design engineers find the arguments for investment casting so compelling. </p><p></p><p>However, this doesn't mean that investment casting is the ideal solution for every application. Like any manufacturing process, it is better suited to some applications than others. So how do you decide whether investment casting is right for your components?</p><p></p><p>In this short mini-guide, we'll take you through some of the key areas to consider if you are thinking of converting a part to investment casting. We'll discuss the common challenges that lead to engineers to think about making a change to investment casting in the first place. We'll look at the three F's of form, fit, and function. And we'll outline some of the cost considerations you'll need to weigh.</p>

Robotic arm moving an investment casting mold

Signicast_Resources_White Papers.png

This mini-guide explores key factors to consider, including common challenges, form, fit, function, and cost, helping you make an informed decision. 

Making The Move to Investment Casting 

This mini-guide explores the key factors to consider when deciding if investment casting is the right manufacturing process for your components, including common challenges, form, fit, function, and cost considerations. 

Making The Move to Investment Casting

<h1>Casting Reliability Reinforced at Lojac</h1><p>Adding a new offering to a business that's going to change the game for construction customers is great, but the last thing anyone wants is for its parts to crumble and repairs to soar.</p><p>Kodi Klip—designed to enhance the intricate task of connecting rebar with increased safety, speed, and strength—experienced two years of growing pains before&nbsp;<a href="https://www.signicast.com/en/about-us/why-signicast">Signicast stepped in to help.</a></p><h2>Casting Reliability Reinforced at Lojac</h2><p>Signicast played a pivotal role in assisting LoJac, Kodi Klip's new majority owner, in transforming this innovative reinforcing solution into a rock-solid success. </p><p>For Tennessee brick-and-block construction manufacturer LoJac, leading the regional building industry with a 75% market share comes with the expectation of reliability.</p><p>When the company discovered inventor Jon Kodi's "Kodi Klip," named Most Innovative Product at a World of Concrete expo in 2015, they were wowed.</p><p>Here was a hand-held, air-gun-like tool that, when triggered, automatically fastens a clip to intersecting rods of rebar. This helped workers to avoid the back-breaking, slow, and injury-prone labour of manual wire-tying.</p><p>(<strong>Casting Reliability Reinforced at Lojac&nbsp;</strong>(alt. description))</p><p>"There's an immediate wow factor, and people totally get it. It's one of those innovations that can seriously change the construction world," says LoJac Chief Operating Officer Kellie Mires.</p><p>The company partnered with Kodi in March of 2016. But the tools that had been produced in its early generations faced a big problem of failure in the field.</p><p>"As soon as it would hit the rebar the nozzle just fell apart," says Aroll Jones, Customer Sales Director for Kodi Klip. "It would be sent back in crumbled pieces."</p><p>By the time LoJac began managing the Kodi Klip business, the product was in its second generation, and LoJac saw firsthand how urgent the reliability issue was.</p><h3>A Solution-Driven Approach</h3><p>Kevin Blair, LoJac's Equipment Director, says "The original nozzle was machined aluminium which was very brittle. We had to add a protector to it after assembly to keep it from being damaged on rebar."</p><p>That brought the part count higher. And the repairs kept coming.</p><p>"We were repairing as many 50 or 60 per month, and more than 80% were because of broken nozzles. You would do a repair, send it back out, and a month and a half later it would come back with another broken nozzle. You can't do that. It's bad for business, bad for the customer, and bad all the way around."</p><p>It became imperative for the company to solve the quality issues before mass-producing a product that would have LoJac's brand attached to it.</p><h2>Converting to Investment Casting</h2><p>Signicast had learned about the nozzle failures from its inventor, so when LoJac took over management of the business, a solution had already been proposed.</p><p>To address the strength issue, Signicast designed a carbon steel solution— a material far stronger than aluminium. "But also, we made it one piece rather than two separate pieces," Ellis says, which would give the nozzle more structural integrity in use. And finally, the new part would undergo&nbsp;<a href="https://www.signicast.com/en/about-investment-casting/investment-casting">investment casting instead of machining</a>, resulting in a stronger and more reliable piece.</p><p>However, the true test would unfold in the field—and within LoJac's equipment shop.</p><h3>Casting a Product That Lasts</h3><p>"In six months, we've put 300 or so into the field, and we have yet to have a nozzle failure," says Blair. "And as more of them get out and replace the older generation, the repairs just keep going down."</p><p>Signicast's solution also yields another benefit: with tooling developed, future production runs can be executed&nbsp;<a href="https://www.signicast.com/en/about-us/automation">with total project automation</a>, just-in-time quantities and schedules prescribed by LoJac.</p><p>"Going with Signicast has made such a big difference. We're finally able to tell the market, 'Yes, you can get it today. Yes, we know it will last,'" says Jones. "When the tool is done, when it hits the field, it's exactly what it needs to be and it's working the way it was designed."</p>

Signicast_Resources_Case Studies.png

LoJac boosts Kodi Klip reliability with Signicast's investment casting expertise. 

Casting Reliability Reinforced at Lojac 

LoJac partnered with Signicast to improve the Kodi Klip's reliability, leading to a stronger product and increased customer satisfaction. 

Casting Reliability Reinforced at Lojac

<h1>Top 3 Design Tips for Investment Casting</h1><p>When designing for investment casting, all of our customers want the same thing, quality components that provide superior performance and durability. This requires sound mechanical design of the final component, reliable process controls, consideration of marketplace economic requirements, and clear communication among all parties. Most of our customers are not familiar with designing specifically for investment casting, so while the below tips are important to remember, we strongly urge you to involve our engineering team early during design to realise the benefits of our knowledge and design efficiencies.</p><p>Contact our team today to get the conversation started.</p><h3>1. Size &amp; Weight</h3><p>Part size and weight are the most critical factors in determining part cost because mould capacity is limited by both. The more pieces that can run on a mould, the lower the part cost. While almost any configuration can be investment cast, our team of engineers can help to optimise your part for the investment casting process by reducing part weight and optimising design geometries. The key to the most cost-effective use of this process is to fully utilise its flexible capabilities and incorporate as many useful features into the cast piece as possible.</p><h3>2. Gating Design</h3><p>The number of gates you have has a direct influence on the cost of your project. The impact of the gate location on the component must be considered during the design phase, as it can be a careful balance between manufacturability, part function, dimensional control, and aesthetics.</p><p>When possible, a part should be designed so that a single gate can feed the part. This will generally yield more pieces per mould and reduce the pour weight per mould. Single gate feeding also enhances the dimensional stability of a given part by providing a directional solidification pattern.</p><h3>3. Component Castability</h3><p>Castability is very important to the investment casting process. Ideally, an investment cast component would be shaped like an icicle for directional solidification—you would pour from heavy to thin. If a design contains features that will raise scrap or rework rates (and piece price), a Signicast estimating engineer will recommend design modifications to help minimise costs.  </p><h3>Quality Investment Castings</h3><p>Early supplier involvement means Signicast's in-house technical staff and CAD capabilities are available to help you to ensure that you receive the best quality component. The design tips above will only help to improve the way your component is investment cast, even if it was previously manufactured by another casting process. Unlike other casting processes, designing for investment casting has a unique set of efficiencies that can be utilised to create the best part for the best price possible<strong>.</strong></p>

Discover essential design tips for optimising investment casting, focusing on size, weight, gating design, and castability, while emphasising the importance of early collaboration with engineering experts for superior results. 

Top 3 Design Tips for Investment Casting 

Key design tips for optimising investment casting include focusing on size and weight, optimising gating design, and ensuring component castability, all while highlighting the value of early collaboration with engineering experts. 

Top 3 Design Tips for Investment Casting

Learn how controlled cooling optimises component geometry and enhances performance. 

SOPHIA® Process 

Considering investment casting for your components? Our free guide helps you determine if it's the right fit based on part size, complexity, and other key factors. Download now for expert insights. 

Investment Casting: Right For You? 

See essential design tips, covering tolerances, repeatability, tool redesign, wall thickness, and more. 

Designing For Performance: Investment Casting Design Guide 

Investment Casting Design Guide

Discover process optimisation strategies, add complex features without increasing costs, and learn from real-world case studies. 

Saving Cost: Fit, Form, Function 

Learn how expert engineers streamline the process, ensuring successful product launches. Watch the on-demand webinar now. 

Prototyping for Production 

Learn how to minimise porosity and maximise part performance in investment casting through optimised part design and gating in this on-demand webinar. 

Minimize Porosity Maximize Performance 

Signicast experts discuss alloy properties, heat treatments, and finishing options for steels, aluminium, exotics like cobalt & Invar, and more. 

Materials Mad Science 

Learn about alloy options and thin-wall casting capabilities to achieve weight reduction without compromising performance. 

Lightweighting Investment Castings with Aluminum 

Learn about the capabilities and benefits of investment casting with CIREX's on-demand webinar. 

Investment Casting Materials and Capabilities CIREX 

Discover faster prototyping, complex component manufacturing, and the advantages of DDM's LAMP™ technology in this informative webinar. 

Investment Casting and Ceramic 3D Printing 

Explore how investment casting efficiently produces complex metal components with high accuracy and various alloy options. 

Investment Casting 101 

Learn from industry experts about a groundbreaking aluminium investment casting process called SOPHIA®, poised to reshape industries needing specialised parts.

Learn how to achieve complex geometries and enhance component performance. 

Design Freedom with Soluble Core 

Learn from real-world examples and see how investment casting can help to achieve design freedom. 

Converting to Investment Casting 

Discover how investment casting can significantly reduce costs compared to CNC machining for large production volumes. 

Can You Cast It? Cost savings through conversion 

Meet Signicast and explore how our approach to automated investment casting enables consistent, scalable precision for critical components.

Introduction to Signicast | Company Video Overview

Introduction to Signicast

Signicast offers unmatched speed, delivering components faster than competitors and reducing inventory needs with their proprietary processes and automation, often achieving turnaround times under a week to help customers reach the market sooner. Their advanced software simulation and patented systems ensure high-quality parts with better repeatability and customer service, making them ideal for producing complex components at the lowest total cost. Additionally, Signicast excels in solving tough design problems by leveraging world-class manufacturing expertise and smart automation, working closely with customers to optimise design and ensure high-quality, precise components with outstanding repeatability.

Signicast Investment Casting Foundry | Wisconsin, USA

Advantages of Signicast Investment Casting

See how Signicast's engineering team collaborates with customers to optimise part performance, manufacturability, and tooling for investment casting.

Signicast Engineering for Casting | Expert Video

Investment Casting Engineering

Signicast Hutchins is an ISO 9001:2015 certified manufacturer specialising in precision investment castings, with a range of products including various steel, stainless steel, and alloy castings. Their in-house capabilities include design engineering support, prototyping, tooling, CAD/CAM, CNC machining, robotic welding, finishing services, and component assembly. The facility produces custom metal castings from 1/4 ounce to 200 pounds for diverse applications.

Signicast Hutchins | Location Spotlight

Signicast Hutchins Location Spotlight

Signicast's Hartford facility is one of the world's most advanced investment casting plants, covering 654,559 square feet and featuring seven fully automated modules for faster lead times. Modules 1-4 and 7 focus on investment casting, while modules 5 and 6 handle value-added operations such as machining, heat treating, final finishing, powder coating, and assembly. The facility uses continuous flow manufacturing, ensuring efficient and seamless production throughout.

Signicast Hartford | Location Spotlight

Signicast Hartford Location Spotlight

The Milwaukee/Brown Deer facility specialises in aluminium and nickel-based alloys. The highly-skilled personnel at the Milwaukee location focus on creating complex cast components that other investment casting operations shy away from. The 98,500-square foot facility utilises the same state-of-the-art technologies as our Hartford facility, but with the flexibility to produce a wider range of complex components—1oz to 200lbs.

Signicast Brown Deer | Location Spotlight

Signicast Brown Deer Location Spotlight

Discover Signicast's investment casting process designed to produce complex, high-precision metal components with superior consistency and efficiency.

Precision Investment Casting Process | Signicast

Investment Casting Process

BraunAbility's innovation, using investment casting, led to the creation of the most spacious wheelchair-accessible minivan. 

Revolutionizing Mobility with Investment Casting at BraunAbility 

Zuti Facemasks: Revolutionizing football safety with investment casting. Stylish, NOCSAE certified, and engineered for superior protection. 

From Welded Steel to As-Cast Solution 

Learn how soluble cores in investment casting enable complex internal cavities, eliminate secondary machining, and increase design freedom while reducing costs. 

Using Soluble Cores in Investment Casting 

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

Streamlined Finishing, Exceptional Results: The Signicast Advantage 

A part's fit, form, and function can determine if it's suitable for investment casting. 

Prototyping For Production FAQ 

Discover various prototyping methods for mass production, weigh their pros and cons, and learn the importance of selecting the right process and collaborating early with suppliers to achieve optimal manufacturing outcomes. 

Prototyping for Mass Production 

Rely on Signicast's nickel alloy casting expertise for parts that demand high strength, corrosion resistance, and heat performance.

Nickel Alloy Investment Casting Solutions | Signicast

Nickel-Based Steel Alloys

Explore medical-grade investment casting with stainless steel, aluminium, and cobalt alloys for high-performance, biocompatible components. Learn about material selection and the importance of a knowledgeable manufacturing partner. 

Medical Grade Investment Castings 

Learn how secondary operations in investment casting can enhance your finished product's quality, accuracy, and capabilities. Discover solutions like machining, surface finishing, and more to unlock the full potential of investment casting. 

Maximizing Investment Casting Potential with Secondary Operations 

Kovar, the ideal alloy for creating strong, hermetic seals in glass-to-metal applications. Signicast offers Kovar expertise and precision investment casting for high-quality components. 

Kovar Spotlight 

Compare investment casting and metal injection moulding in this blog to discover which process is best for your metal component production needs. 

Investment Casting vs MIM: A complete guide 

Invar 36, a nickel-iron alloy with a low coefficient of thermal expansion, ideal for precision applications in aerospace, automotive, and more, offering cost-effective casting solutions. 

Invar 36 Spotlight 

See how gating, solidification, and material selection influence porosity in investment casting. Discover how strategic gate location, optimised part design, and informed material choices can lead to successful, high-quality castings. 

Gating and Solidification: the Key to Elimination Porosity  

Discover how to optimise part designs, select the right alloys and heat treatments, and leverage DFM to reduce costs and enhance the quality of your components. 

Fit, Form, Function FAQs 

Converting to Investment Casting: Is Your Part a Good Fit? 

Download this whitepaper to learn how Signicast meets aerospace and defence requirements through certified alloys, repeatability, and lead time control.

Aerospace & Defense Castings | Signicast Whitepaper

Casting Solutions for Defense and Aerospace

This article highlights how Signicast investment casting excels in maintaining the rigorous requirements of the aerospace and defence industries.

Resources

Trending

Article

Article

Webinar

Making The Move to Investment Casting

Case Study

Article

Articles

Article

Article

Article

Article

Article

Article

Article

Article

Article

Article

Article

Article

Article

Article

Article

Article

Article

Article

Case Studies

Case Study

Case Study

Case Study

Videos

Video

Video

Video

Video

Video

Video

Video

Webinars

Webinar

Webinar

Webinar

Webinar

Webinar

Webinar

Webinar

Webinar

Webinar

Webinar

Webinar

Webinar

Webinar

Whitepapers

White Paper

White Paper

White Paper

White Paper

Interested in starting your investment casting journey?