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<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 labor 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 aluminum 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 aluminum. “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>

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Discover how Signicast delivered consistent quality for Lojac’s high-demand components, improving uptime and reducing defect rates.

Reliable Casting for Lojac | Signicast Case Study

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>From Welded Steel to As-Cast Solution</h1><p>Between clunky, welded-steel prototypes and a few discouraging production runs, John Pizzuti experienced firsthand the expense of using other methods and suppliers to bring his game-changing football facemasks to market.</p><p>Then, he looked to <a href="https://www.signicast.com/en/about-us/why-signicast%22%20/t%20%22_blank">Signicast’s engineering expertise</a> to manufacture his innovative designs more competitively – while protecting the competitors who wear them.</p><h3>Elevating Safety and Style</h3><p>Introducing new uniforms, logos and design elements is a popular strategy for US football teams to enhance their identities. Whether bold or subtle, these occasional redesigns can bolster fan merchandising, attract attention for recruitment, or raise awareness for sponsors and causes.</p><p>But what they can’t do is interfere with player safety.</p><p>Partly because of this, the facemask, seemingly a front-and-center opportunity for team expression, has been excluded from branding changes in pro and college leagues.</p><p>(<strong>From Welded Steel to As-Cast Solution&nbsp;</strong>(alt. description))</p><p>After all, the main role of a facemask is protection, so league rules and certification standards have discouraged modifications to its most basic design.</p><p>John Pizzuti wanted to give masks a facelift to match the evolution of football uniforms, while still focusing 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’d been built for decades,” says Pizzuti. “Welding together quarter-inch, cold-rolled steel.”</p><p>When he was done, he wasn’t happy with the way they looked – and it had taken a month to build them. “There was no way I could turn a profit,” he says.</p><p>Pizzuti got advice from his mentor, a long-time auto industry professional who also happens to be his mother. She suggested he switch to casting.</p><p>“A light bulb came 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 stylized elements into the grille, creating a potential platform for branding.</p><p><em>“With </em><a href="https://www.signicast.com/en/about-investment-casting/investment-casting"><em>investment casting</em></a><em> comes geometric advantages that we could build into these 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 ran into obstacles, as they faced challenges with non-fill and scrap issues, leading to low percentages of viable parts.</p><p>That’s when he was contacted by Lann Ellis of Signicast, who was intrigued with a Modern Casting article about Zuti Facemasks. “This project could be a disruptive innovation for leagues,” says Ellis. “I figured with our engineering resources, Signicast could drive Zuti into .”</p><p>The timing was good for Pizzuti. <strong>“</strong><em>Every time Lann would call, he would give me a new value-added strategy that we could implement, whether it was a way to reduce costs, or gain economies of scale.</em><strong>”</strong> So, Zuti Facemasks made the switch to Signicast.</p><p>Behind the scenes, the diverse engineering team at Signicast – 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 nimble enough to allow Pizzuti to make changes quickly, says Ellis. And it meant that they could deliver a higher-quality facemask.</p><h3>Innovation Achieves Superior Safety Standards</h3><p>Following the debut of the initial <a href="https://www.signicast.com/en/about-investment-casting/prototype-casting">prototype from Signicast</a>, Zuti Facemasks knew it had a winner on its hands.</p><p>“I could tell from looking at it 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 mentions that although the surface finish of an investment cast part could 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 just that much better. There was less shrink. <em>It was overall a better-quality part</em><strong>,”</strong> Pizzuti says.</p><p>Since Zuti Facemasks uses an innovative design, and a <a href="https://www.signicast.com/en/about-investment-casting/investment-casting-process">manufacturing process</a> 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 facemasks passed.</p><p>This is good news for youth, high school and college football teams and leagues who need to be confident that their equipment is safe.</p><p>And, equally appealing to teams who demand a more notable appearance on the field, Pizzuti says, “it just looks a lot sweeter.”</p>

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

Steel Welded 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 facemasks using investment casting. 

From Welded Steel to As-Cast Solution

<h1>Revolutionizing Mobility with Investment Casting at BraunAbility</h1><p>Because of the intricate mechanisms needed to allow wheelchair users to enter and exit safely, gaining more space requires intricate modifications to the vehicle’s factory-supplied suspension.</p><p>“In the past, Chrysler used a much simpler design, the solid rear axle,” says Sajed Dosenbach, a Design Engineer at BraunAbility. “But in the newer design, the independent rear suspension was a lot more complex.”</p><p>Ultimately, this meant the company’s usual in-house fabrication capabilities simply wouldn't be feasible.</p><p>Dosenbach knew <em>investment casting would ease the complexity of manufacturing by consolidating parts</em>—not to mention delivering higher strength than sheet-steel stamping—so he gave Signicast a call.</p><h2>Design for Manufacturability</h2><p>To implement this new modification, cradle mounts needed to be seamlessly integrated into the Chrysler-designed subassembly beneath the car, resembling the way a trailer hitch effortlessly slides into a sleeve-like hitch receiver. </p><p>Given that this suspension had never been attempted before, Dosenbach had to initiate the process with only an idea, which he then translated into a CAD drawing. It was Signicast’s job to help him transform that idea into the components BraunAbility needed.</p><p>Before investing the time and cost of tooling up for a production run, Signicast needed to verify the manufacturability of this entirely new design and ensure it would meet BraunAbility’s rigorous safety and durability testing standards.</p><h3>In-House Prototyping Capabilities</h3><p>After running simulations, Signicast’s engineers made CAD models of several design options. Utilizing in-house prototyping capabilities, they transformed 3D printed patterns into production-intent steel prototype parts—exact replicas of the part—on which BraunAbility could perform its real-world tests.</p><p>As Dosenbach explains, “That's the <strong>best prototype you could ask for</strong> because it accurately replicates the final production piece in terms of strength. When prototyping instead of producing a final part, you’re essentially altering the manufacturing method.”</p><h3>Preventive Prototyping</h3><p>Most importantly, the ability to revise and improve on the idea using Signicast’s prototyping capabilities led to a successful, workable design.</p><p>For example, some test results on the prototype showed that the original design would require greater welding surface area to maintain joint strength. A better solution was to invert a portion of the design—a far easier and more affordable fix during prototyping than after a production run.</p><p>After the new design was prototyped in different versions, BraunAbility retested the part—and it passed. “Going through Signicast’s prototyping process was a lot quicker than coming up with a whole new original design, and <em>saved us from wasting money on tooling</em>,” says Dosenbach.</p><h3>The Most Spacious Wheelchair-Accessible Van on the Road</h3><p>The BraunAbility Pacifica is gaining traction as the most spacious wheelchair-accessible van on the road. The suspension clearance project, along with</p><p>modifications to the interior floorboard, resulted in nearly 20% more space for wheelchair passengers.</p><p>“BraunAbility was able to cut inches off the van floor and put their new modified floorboard on,” says Lann Ellis of Signicast. “They’ve captured extra room, and now have the largest cabin space of any modified minivan on the market.”</p><p>For Dosenbach, Signicast’s software simulations, real-world prototypes, part consolidation, and in-house machining made the whole project easier to achieve. “The requests I made to Signicast for these parts were very complex on their end. And they always got me what I needed,” he says.</p><p>The project also means that wheelchair passengers can now move fully 360 degrees around inside the vehicle’s interior.</p><p>And for BraunAbility, that translates to a movement of happy customers.</p>

See how Signicast helped BraunAbility consolidate parts, reduce weight, and speed production to improve mobility and comfort for wheelchair users. 

Wheelchair-Accessible Van Case Study | Signicast 

BraunAbility partnered with Signicast to utilize investment casting and prototyping, resulting in the creation of the most spacious wheelchair-accessible minivan on the market, providing greater mobility and comfort for wheelchair users. 

Revolutionizing Mobility with Investment Casting at BraunAbility

<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 molding (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 molding. 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 mold 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>Investment casting, 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 mold. The mold is then coated with layers of ceramic slurry and rapidly dried to harden the shell. Once dry, the mold is put into an autoclave to remove the wax from the mold. Molten metal is then added to the mold 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 IC and MIM produce strong, durable parts using a wide variety of alloys. For MIM, OptiMIM’s distinguishing factor is custom feedstock and the ability to specify metal particle size distribution and develop unique binder compositions. This makes the process fully customizable 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 specializes 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 material options are nearly endless. At Signicast, we pour everything from 400-series stainless steel and plain carbon steel, to nickel and aluminum. 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 favor 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, rapid prototyping and secure supply chains make it the perfect solution for a variety of industries. Stainless steel is especially efficient for industries that require high strength and temperature resistance like  aerospace and defense applications. Our specialized 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 molding, download our free, on-demand webinar on IC vs. MIM by completing the form below. </p>

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

MIM vs Investment Casting | Process Comparison

See investment casting and metal injection molding 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>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 realize 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 mold capacity is limited by both. The more pieces that can run on a mold, the lower the part cost. While almost any configuration can be investment cast, our team of engineers can help to optimize your part for the investment casting process by reducing part weight and optimizing design geometries. The key to the most cost-effective use of this process is to fully utilize 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 mold and reduce the pour weight per mold. 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 minimize 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 utilized to create the best part for the best price possible<strong>.</strong></p>

Boost casting success with these design tips: simplify geometry, add fillets, and plan for shrink—straight from Signicast engineers.

Top Design Tips for Casting | Signicast Article

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

Top 3 Design Tips for Investment Casting

<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 minimizes 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 specialized 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>

Discover how in-house finishing, machining, and automation help Signicast deliver final parts faster with tighter control over quality.

Finishing & Machining in Casting | Signicast Article

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>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 utilize 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 labor 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>

Understand what really matters—quality systems, process control, design support, and turnaround—when selecting a casting partner.

Choosing a Casting Supplier | Signicast Article

The top five critical factors to consider when selecting an investment casting company, including quality, speed, delivery, and cost efficiency, emphasizing 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>Nickel-Based Steel Alloys</h1><p>While the investment casting process is capable of pouring almost any alloy, our most popular alloys are in the nickel family. Consisting primarily of nickel, chromium, and molybdenum, nickel-based alloys are among the most widely used investment casting materials. The most popular being CW2M.</p><p>Creating a nickel-based alloy takes great precision and skill. At Signicast, we pay very close attention to the composition of the material we melt to ensure we create superior alloys. Our casting process creates very metallurgically clean castings with excellent weldability.</p><h3>What Industries Use Nickel-Based Alloys?</h3><p>Any industry can use nickel-based alloys, but the majority of our customers who use them are looking for the best corrosion resistance in oxidizing environments. Additional elements like molybdenum and chromium are added to create an alloy that is arguably one the world’s toughest.</p><p><em>When should you use a Nickel-based Alloy? </em> If 300 series stainless steels do not cut it, nickel-based alloys are great for components used in the chemical and process industries. Additionally, meter bodies used in chlorine and acid services utilize CW-2M for its excellent mechanical and physical properties. </p><h3>High-Performance Alloys</h3><p>Nickel-based alloys are part of the super alloy family, also known as high-performance alloys. As well as being highly resistant to corrosion and oxidation these alloys are harder and stronger and corrosion resistant at higher temperatures making them a great option for welding applications. Some alloys lose corrosion resistant when you raise the temperature, nickel-based alloys do not. They also have great ductility and can be easily fabricated.</p><p>Signicast offers everything from 400 stainless steel to aluminum. We are committed to giving you the very best performing part at the lowest total cost. </p><h3>Did You Know?</h3><p>Hastelloys are name brand nickel-based alloys invented by Haynes International in 1912. The original patent expired allowing manufacturers to develop “generic” or off-brand “Hastelloys”. For example, our CW-2M is equivalent to Hastelloy C. So while the name itself may be different, the alloy acts and performs just like the original Hastelloy.</p>

Get to know Signicast’s nickel-based alloys, combining heat resistance and toughness for parts exposed to extreme service conditions.

Nickel Steel Casting Options | Signicast Article

Nickel-based alloys, known for their exceptional corrosion resistance and strength at high temperatures, are a popular choice in investment casting at Signicast, particularly in demanding applications like chemical processing and chlorine services. 

Nickel-Based Steel Alloys

<h1>Invar 36 Spotlight</h1><p>Invar 36[1], also known within the industry as Nilo 36[2], is a nickel-iron superalloy known for its low coefficient of thermal expansion. Containing 36% nickel, it maintains nearly constant dimensions as well as good strength and hardness over a wide range of temperatures. Invented in 1896 by Swiss physicist, Charles Edouard Guillaume, Invar was created as a low-cost solution to a meter once made of platinum and iridium. Guillaume’s work led to the discovery of a fairly inexpensive iron-nickel alloy—a steel-like material—that expands very little when heated. He named the alloy Invar because it was almost unchanging or "invariable.”</p><h3>Invar 36 Success</h3><p>One of our customers came to us specifically wanting to use INVAR 36 for a component requiring the near constant dimensions and long-term dimensional stability this alloy is known for<em>.</em> Due to confidentially agreements, we cannot name the customer but what we can tell you, is that like with many other projects, Signicast engineers rose to the challenge to not only cast Invar 36 successfully but completely exceeded the customers’ expectations—all while saving them money. Because after all, isn’t that the end goal? Create a quality component at the lowest total cost. </p><p><em>Why did our customer need Invar 36</em>? The slightest change in dimension or shape of their component could alter their end product—even though they were already in a temperature controlled room. A few degrees could alter the function of the part. They knew they needed to work with a material like Invar 36 but machining it from solid became costly.</p><p><em>How did Signicast help?</em> We had never worked with Invar 36 in the past, but there has never been a challenge our engineers didn’t at least try to overcome. With some research and testing we came up with a casting material that actually performed as good or better than wrought and we were able to cast net-shape successfully. Not only did we add savings on final part cost because they didn’t have to machine the part, but our final part cost was actually cheaper than their original block of metal—prior to machining.</p><p><em>The end result?</em> A very happy customer who saved tenfold and a new material added to our offerings.  </p><p>Invar 36 maintains nearly constant dimensions at temperatures below -150 degrees Celsius up to 260 degrees Celsius.</p><h3>Who Should Use Invar 36?</h3><p>Customers who are under strict temperature constraints will likely see the advantages of using Invar 36. Unfortunately, those who are currently machining from solid do not realize that casting net-shape is even an option. In today’s world, Invar 36 is often used in measuring devices, precision mechanical systems, laser components, thermostat rods, meters and components that transport liquefied gases—to name a few.</p><h3>Invar Industry Applications</h3><p>Invar can be used in a variety of applications within the aerospace, medical, and consumer electronics industries. But where superalloys with low CTE are really starting to outperform other metals is in technologies within the automotive industry. As autonomous vehicles rise in popularity, sensors, radars, and cameras become increasingly advanced and critical to the function of the car. LiDAR, an acronym for light detection and ranging, uses light waves from a laser to calculate how long it takes for the light to hit an object or surface and reflect back to the scanner—determining the distance of surrounding objects. An alloy with near constant dimensions and long-term dimensional stability, such as Invar 36, is extremely important in such intricate devices. Alternative alloys, like Kovar, with low CTE are also viable options for casting LiDAR sensors. Investment casting is a cost-effective solution compared to machining LiDAR parts from solid.</p><h3>What are the Advantages of Invar 36? </h3><p>The most obvious advantage of Invar 36 is its ability to hold dimensions at cryogenic temperatures. Aside from that, Invar 36 looks and feels similar to steel. It also has outstanding weldability and machinability. Invar can also be created with customized chemistries to better meet the strength and hardness needs of customers. </p>

Learn how Invar 36 delivers ultra-stable dimensions under thermal stress, serving aerospace, optical, and cryogenic applications.

Invar 36 Investment Casting Benefits | Signicast Article

Invar 36 is a nickel-iron alloy known for its low coefficient of thermal expansion, making it ideal for applications requiring high dimensional stability across a wide temperature range, such as in precision mechanical systems, aerospace, and automotive technologies. 

Invar 36 Spotlight

<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 prioritizes 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>Kovar’s thermal expansion 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 oxidizing 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 behavior 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, rapid prototyping and delivery, and the most advanced investment casting facilities 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 in-house engineers, 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.

Kovar Spotlight

<h1>Using Soluble Cores in Investment Casting</h1><h2>Do your metal components require complex inner cavities?</h2><p>Investment casting is ideal for parts that require tight tolerances, repeatability, and complex design characteristics. For parts that require particularly complex inner cavity configurations, our design engineers can incorporate a soluble core into the investment casting process. The use of soluble cores allows for more intricate cavity patterns to be included in the casting, reducing or eliminating the need for additional machining.</p><h2>Designing for soluble core</h2><p>Incorporating a soluble core into the investment casting process is achieved through strategic design and a few additional steps to our advanced investment casting process.</p><p>During the standard investment casting process, the pattern wax is injected into the mold cavity, cooled, ejected, and then attached to the sprue before continuing on for the remainder of the casting process. If the part does not require a particularly intricate core, this process is automated with our state-of-the-art technology. If the part does require an inner channel, the soluble core process is best-achieved by one of our specialized operators.</p><p>First, a soluble wax is injected into a mold to form the geometry of the core. The core is then ejected from the mold and cooled.</p><p>An operator will mount the soluble core in a precise position within the cavity of the mold for the entire component. The position of the soluble core within the mold is held by points of support that are incorporated into the mold during the design process. The added support ensures that the core stays in place when the pattern wax is injected and helps to facilitate the removal of the wax from the mold. The mold is then closed and the pattern wax is injected into the cavity around the soluble core. In the mold, the soluble core creates the inner baffles, channels, and ports that will be included in the final casting.</p><p>Once the pattern wax is cooled, the whole part is ejected from the mold. The part is then inserted into a bath of mild muriatic acid, and the soluble core is dissolved out, leaving behind a geometrically complex core that could not be otherwise achieved with standard investment casting.</p><p>The remaining pattern wax is then attached to the sprue and continues through the remainder of the investment casting process as normal. The end product is a repeatable, intricate part that delivers high performance without demanding costly secondary operations.</p><h2>So why soluble cores?</h2><p>Utilizing soluble cores provides many benefits, but the biggest benefit is the ability to design components with more complexity in the core of the part without costly secondary operations.</p><p>Without the need for additional machining, engineers enjoy greater design freedom. Additionally, the elimination of secondary operations mean that you’ll save time in the manufacturing process, and therefore, save on manufacturing costs.</p>

See how Signicast uses soluble wax cores to create complex internal features, enabling functionally integrated casting designs.

Soluble Core Wax in Investment Casting | Signicast Article

Soluble cores in investment casting allow for the creation of complex internal cavities within metal components, eliminating the need for secondary machining and offering greater design freedom while reducing manufacturing costs.

Using Soluble Cores in Investment Casting

<h1>Converting to Investment Casting: Is Your Part a Good Fit?</h1><h2>What makes your part a good fit for investment casting?</h2><p>When deciding on the best manufacturing process for a precision metal component, the design, cost, and timeframe allotted for production drive the conversation. If something isn't working as well as it should with your current process, you might start looking for alternatives.  </p><p>The manufacturing process chosen can significantly impact the final result. This is why many design engineers find the idea of converting to investment casting compelling.</p><p>Investment casting lets you cast almost any shape, in any alloy, with sophisticated and complex design features—all to exacting tolerances at a lower overall cost. Whether inefficiencies, added costs, or part variance plague your current process, converting to investment casting can add value to your project.</p><p>This blog will outline the three F’s of form, fit, and function that make a part a viable candidate for the process.</p><h2>Fit, form, and function</h2><p>When evaluating the suitability of an existing part for investment casting, these three areas are key:  </p><ul><li>Where will the part fit?</li><li>What form will it take?</li><li>How does it need to function to deliver maximum value?</li></ul><p>The answers to these questions determine whether investment casting is a good alternative to your current process.</p><h3>Fit</h3><p>Understanding how the part fits within the final product is important. For instance, is it currently part of an additional assembly process? This helps identify areas where you may gain greater value by simply recreating an existing part using investment casting.</p><h3>Form</h3><p>Consider whether the part has a simple or complex geometry. While investment casting can produce almost any level of geometric complexity, it's with highly complex components that the process offers the most significant return on investment. More traditional shapes like wedges or cope-and-drag style boxes are possible with investment casting, but it may not be as cost-effective as a simpler process like sand casting.</p><h3>Function</h3><p>Focus on the part's function. Is the component static or moving? Does it need to withstand impact and constant wear? Must it sit flush against another part in a way that can be pressure sealed? This gives critical information about the best-suited alloy. Being open to adjusting the alloy formulation used with a different process might lead to improved part performance with investment casting.</p>

Evaluate whether your part is right for casting by reviewing key geometry, material, and cost factors in this engineering-focused article.

Is Your Part Right for Casting? | Signicast Article

See how a part's fit, form, and function can determine if it's a good candidate for investment casting, a process that offers superior design flexibility and cost savings compared to traditional methods.

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

<h1>Prototyping for Production FAQ</h1><p>When it comes to designing and developing your components, developing a prototype is one of many critical steps towards successful program launch and efficient mass production.</p><h2>How to choose the right prototyping method?</h2><p>While 3D printing is gaining popularity, selecting a metal prototyping option requires careful consideration. It's essential to start with the basics and evaluate the cost impact of various factors for 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 due to their impact on cost. Specific features and properties will be more suitable for one process over another. Additionally, it's necessary to determine if the prototype will serve solely as proof of concept or if a fully functional part for real-world testing is required.</p><p><strong>Rest assured, a team of engineers can help determine the ideal prototyping option for any project.</strong></p><h2>Prototyping stage for alloy selection</h2><p>The prototyping stage offers an excellent opportunity to test different material options. With&nbsp;investment casting. multiple material options can be explored during prototyping. For instance, 3D printed patterns can be used instead of traditional wax patterns, allowing engineers to print multiple patterns and run them through different molds 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 tool room, tools and fixtures are built concurrently. The tool room operates continuously, just like the foundries, ensuring no time lapses. Since there's no reliance on external sources for tool building, standard tooling lead times are three to five weeks.</p><h2>In-house production machining capabilities</h2><p>Both in-house production machining and machining for prototyping are available. A well-equipped machine shop houses three, four, and five axis machining centers with a wide range of capabilities.&nbsp;Plant tours&nbsp;are available for those interested in seeing the facilities firsthand.</p><h2>Differences between manual tool and mass production tool parts</h2><p>Generally, there are no significant differences. A manual tool limits injection speed, so the main distinction lies in the injection rate. A fully productionized tool allows for automated presses and robotic part removal associated with a full-fledged investment casting run. For prototyping projects with higher volumes, a production tool environment offers greater efficiency.</p><h2>Available non-destructive testing (NDT) processes for investment cast prototypes</h2><p>A variety of NDT testing procedures are available, including fluid penetrant injection (FPI), mag particle inspection, X-ray, test bar, dimensional scanning, and coordinate measuring (CMM). Regardless of the testing requirements, whether during printing or post-production, 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's no need to compromise quality for time or cost.</p><p>To learn more about utilizing investment casting for prototyping, fill out the form below to access our free on-demand webinar.</p>

Explore answers to common questions about prototyping cast parts, including tolerances, timelines, and transitioning to tooling.

Prototyping FAQs for Investment Casting | Signicast Article

Prototyping For Production FAQ

<h1>Prototyping for Production FAQ</h1><p>An effective prototype should be more than a mere replica. It should be robust enough for strength testing, accurately represent the final part's geometry, and serve as validation of 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 cater to specific project needs, and our team of engineering experts has extensive experience producing prototypes across various industries and applications.</p><h2>Prototyping options for productive 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 will help narrow down the available options.</p><h3>Short-run, hard tooled prototype</h3><p>If a prototyping process is needed 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 compared to processes using SLAs or PMMAs. If a project demands 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 to replicate the mechanical properties of an investment cast component, 3D printed wax patterns offer efficiency and a quick turnaround. These patterns are produced in-house within hours and are immediately transformed into functional metal components. Recent technological progress has simplified the validation of surface finishes on these prototypes. The primary constraint of this process is component size, as printers can only handle parts roughly the size of a Rubik’s cube or smaller.</p><p><em>A 3D printed wax pattern and the cast prototype</em></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, besides 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. Similar to 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 serves as a good indicator 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 most suitable for low-volume aluminum 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 appropriate for prototypes with intricate geometries and precise, untoolable features. However, it's 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 might 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 might be utilized. The optimal prototyping process for any given testing stage depends on the project's scope and proximity to product launch.</p><p>As the project nears mass production, transitioning to a short-term hard tooled investment casting run is recommended. This allows for comprehensive testing and validation of all requirements for the final component.</p><h3>Maximizing 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 optimal manufacturability 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 mold flow and solidification, castibility, or alloy compatibility.</p>

Learn how investment casting bridges prototype validation and full production, with consistent results and accelerated lead times.

Prototyping for Production Scale | Signicast Article

Various prototyping methods exist for mass production, each with its own advantages and drawbacks, and selecting the right one depends on project needs and early supplier collaboration for optimal outcomes. 

Prototyping for Mass Production

<h1>Medical Grade Investment Castings</h1><p>The healthcare industry constantly evolves, and recent years have seen an increased need for innovations in medical technology and portable, durable devices. Simultaneously, there's a growing demand for medical components that are not only high-performing but also compatible with the human body over sustained use.</p><p>For many years, stainless steel was considered the only material suitable for manufacturing medical equipment. However, aluminum and cobalt chromium alloys have recently found a place in the medical market.</p><p>Signicast investment castings leverage each of these alloys, along with precision capabilities and tight tolerances, for the best performance in the industry.  </p><h2>Stainless steel alloys for medical-grade equipment</h2><p>While innovations in materials for the medical industry are ever-changing, stainless steel remains a top choice for most medical equipment manufacturers due to its low and high-temperature resistance, high strength, and biocompatible properties. Investment casting allows for the engineering of necessary complex geometries into the casting, enhancing part performance and reliability. Signicast's stainless steel alloys include different combinations of nickel, chromium, and carbon. Depending on the application, one can choose between the 300 or the 400 series stainless steels.  </p><ul><li>The 400-series comprises 25% nickel, 1% carbon, and 11-27% chromium.</li></ul><ul><li>The 300-series contains 6-25% nickel and 16-30% chromium.</li></ul><p>If high strength and cost reduction are priorities, the 400-series might be the right choice. However, for applications needing high strength, high corrosion resistance, and property retention at high temperatures, the 300-series group could be more effective.</p><p>Connecting with a Signicast metallurgist is recommended to determine the best-suited material for specific requirements. There might be an option available that hasn't been considered yet.</p><h2>Aluminum alloys for Class 1 &amp; 2 devices and housings</h2><p>While stainless steels meet biocompatibility and strength requirements for Class 1 and 2 medical devices, their weight can be a limiting factor in usability. Aluminum alloys often offer lower total costs while maintaining a significantly higher strength-to-weight ratio compared to stainless steels. Additionally, aluminum inherently creates aluminum oxide when exposed to oxidizing agents, forming a protective layer that prevents further oxidation and weakness of the component. This is where lightweight aluminum has found its place in the market, producing medical components for applications like handheld surgical devices and portable medical equipment that need to be durable, lightweight, and easy to use while also passing stringent FDA regulations.</p><h2>Cobalt alloys (ASTM-75) for implantable devices</h2><p>Signicast has utilized cobalt alloys as an alternative to stainless steel,</p><p>particularly for implantable devices. Cobalt-Chromium, which is ferromagnetic, is very strong even at very high temperatures and has high corrosion and wear resistance compared to other metals. It is also entirely biocompatible, making it suitable for implantable devices.</p><h2>Medical component manufacturer</h2><p>Medical devices, whether Class 1 or 2, have components that should meet and/or exceed the necessary efficiency and safety requirements set by governing bodies, as well as the physical and mechanical properties required by the manufacturer. This calls for extra care when choosing the material for such devices and the right manufacturing partner for a successful program launch.</p>

See how Signicast meets rigorous biocompatibility, cleanliness, and dimensional standards for implantable and surgical-grade cast parts.

Medical-Grade Castings | Signicast Industry Article

Medical grade investment casting utilizes stainless steel, aluminum, and cobalt alloys to produce high-performance, biocompatible components for diverse medical applications, demanding careful material selection and a knowledgeable manufacturing partner. 

Medical Grade Investment Castings

<h1>Gating and Solidification: The Key to Eliminating Porosity</h1><p>When turning to the investment casting process, it is important to understand all of the factors that go in to making a successful part. One of the first steps to avoid part failure is to ensure the required soundness of a part before it is cast. Investment casting is one of the few manufacturing processes that can preliminarily demonstrate component success. </p><h2>Gating systems</h2><p>When designing an investment cast part, the gate location and size must be taken into consideration. The gate is a small opening that allows molten metal to flow freely to the cavity and can be thought of as the connection point between the feeding source, or sprue, and the part. The gate is ideally located on the thickest and heaviest section of the casting, allowing the metal to continuously flow and fill the part in its entirety before solidifying.</p><h2>How Metal Solidifies During Casting</h2><p>Metal solidification is a critical factor in understanding gating. As molten steel cools from its initial pouring temperature of approximately 3000°F to its solidifying temperature of roughly 2500°F, it undergoes volumetric shrinkage. This shrinkage continues as the metal solidifies and then again as it cools to room temperature, due to thermal expansion.</p><p>To illustrate, a 1" x 1" x 1" cube, when filled with molten steel, will shrink to approximately 0.96" x 0.96" x 0.96" at room temperature. This volumetric change necessitates careful consideration of part geometry and gate location and size. Proper design ensures that the casting is continuously fed with liquid metal to compensate for shrinkage as solidification progresses.</p><h2>What makes a successful cast part?</h2><h3>Gate location and size</h3><p>After understanding the basics of metal solidification, we can start to determine the size and location of the gate. If gate details are not taken into account, the gate could solidify before the metal has the opportunity to fill the casting and replace lost volume. This could create large pockets within the part that are not fully filled, also known as internal porosity. Porosity refers to the level of solidity achieved, that is, whether there are cavities or holes within the part. If a component is not carefully gated with part function in mind, this could lead to part failure.</p><h3>Part design</h3><p>The gate is not the only determining factor in eliminating porosity. Part geometry can impact the directional solidification of the metal. The design must account for making thermal gradients steep enough to keep the feed paths clear from the sprue to the part. Since parts do not solidify all at once, and they cool from the outside in, a quality design will allow for the metal to cool away from the gate, first. An icicle shape is the prime example of a perfect casting, with the tip freezing first and the remainder of the icicle freezing from the smallest sections back through to the thickest section (the water source).</p><p>In designs that show initial porosity, adding features like feed ribs can eliminate any unwanted pockets. Part design can also be enhanced with structural changes, like tapering bottom floors, to reduce porosity. In some instances, however, part geometries cannot be altered. We can take advantage of radiant heat, designing the gate with inconsequential arms that keep thin walls hot enough to feed the part, including end plates, as it solidifies.</p><p>In working closely with customers, Signicast design engineers are able to better understand part function and optimize part geometry to meet the requirements of the application.</p><h2>Casting Material Selection</h2><p>In addition to design considerations, material choice directly impacts porosity within a part and the solidification of a casting. Each element within an alloy has different solidifying temperature, making an alloy like 17-4 stainless steel have a larger temperature range as it goes from a liquid to a solid due to the amount of elements within the alloy. The large temperature range inhibits flow, making it less forgiving than a low carbon steel. Knowing material requirements on the frontend of the project, design engineers have a better opportunity to predict part success and limit porosity before moving to the tooling stage.</p><p>Before heading into full production with a part design, it is important to identify potential porosity issues. At Signicast, we use solidification and flow software to determine the efficacy of gating locations and predict casting porosity to validate the design. Our design engineers can help make beneficial design suggestions that will result in successful parts without delaying time to market.</p>

Dive into how optimized gating and controlled cooling eliminate voids and ensure structural soundness in investment cast components.

Shrink Porosity Solutions | Investment Casting Article

Gating and solidification are crucial in investment casting to eliminate porosity; gate location, part design, and material selection directly impact the success of castings. 

Gating and Solidification: the Key to Elimination Porosity

<h1>Fit Form Function FAQs</h1><p>Part design is crucial to the success of any component. It's essential for the overall success of a project to remain on track in terms of timelines and deliverables. A supplier requesting a design for manufacturing review may seem like a potential hindrance, but an initial design review at the project's outset could save costs related to the fit, form, and function of the part, thanks to input from design experts. Below are some frequently asked questions about the investment casting process and how our team of highly trained engineers can enhance the design of parts.</p><h2>Is my part too heavy for investment casting?</h2><p>Just like any other manufacturing process, there are limitations with investment casting. In multiple steps throughout the investment casting process, the molds must meet certain weight requirements. Molds themselves have weight restrictions based on the type of alloy poured, maxing out at 100 to 120 pounds and meeting the industry weight standard. At other stages, molds are handled manually, or even automatically by Signicast’s state-of-the-art automation and robotics systems, requiring strict weight and safety restrictions.</p><h2>Does surface area cause limitations?</h2><p>There are three areas in which surface area has limitations—dip cells for the ceramic shell-building process, dewaxing where steam pressure is used to remove the wax from the shell, and then the burnout ovens.</p><h3>Dip</h3><p>The more surface area the part has, the more viscous slurry sticks, increasing the weight of the sprue and causing weight limitations for the robot.</p><h3>Dewax</h3><p>Now that there is a fully injected and dipped mold, there is the weight of the wax and the added weight of the ceramic shell. In this stage, there are personnel safety weight limitations to safely transport the molds in the plant.</p><h3>Burnout Oven</h3><p>The molds are fired to 1800℉, and once the temperature is reached, it's essential to ensure that the molds are still handled safely.&nbsp;</p><h2>How do I take full advantage of the investment casting process?</h2><p>As previously mentioned, almost every design will likely encounter a geometry, pour weight, or shell weight limitation during the initial mold design phase.</p><p>However, through a Design for Manufacturing (DFM) meeting, the&nbsp;Signicast engineering team collaborates to address potential limitations, increasing the value of the part from the outset. The part effectively "rents" space on a mold, so any changes or features added to the design are essentially free, as long as the footprint of the mold remains unchanged.</p><p>For instance, holes or bosses can be added to the design without increasing the overall footprint of the part. The number of pieces on the mold, as well as the piece part price, will stay the same. Small price implications might be added to the tool cost.</p><p>In a recent project, the Signicast Engineering team reduced a customer's piece part price from $23 to $18—a cost reduction of almost 30%. This price reduction wasn't due to the alloy cost, but rather a design change that allowed for more pieces per mold. The initial customer DFM session also leveraged the full benefits of the investment casting process by adding lettering, lot codes, part numbers, and logos on the parts at no additional cost.</p><h2>When should I consider alloy and heat treatment selection?</h2><p>Alloy selection and heat treatment are often considered early in the design process and not revisited later.</p><p>Some customers utilize cutting and grinding tools. A knife blade design, initially machined from solid 420 steel, was brought in for review. After discussing the part's function and conducting a DFM call, the in-house metallurgist suggested D2 tool steel. The result was a sevenfold increase in wear resistance, significantly extending the part's service life.</p><p>Considering heat treatment is also crucial. For parts requiring heavy machining, heat treatment and homogenization of the material before machining are recommended to minimize hard spots and broken tools. However, if extensive machining isn't necessary, heat treatment might be eliminated entirely.</p><h2>How can I eliminate machining and ultimately cut costs?</h2><p>By simply designing an investment casting with certain features, machining can be avoided, eliminating a significant cost associated with the part.</p><p>The engineering team frequently encounters prints with surface finish callouts. This often adds unnecessary costs. Many features machined on the casting are for size, position, or flatness. A surface finish callout is only necessary if it's for a sealing surface, O-ring groove, or a press fit. The DFM process can often help eliminate one or two machine passes, or even reduce the overall machining cycle time.</p><h2>How long does a DFM meeting take?</h2><p>The meeting duration typically ranges from 15 minutes to an hour, depending on the part's complexity and the potential areas for improvement identified by the engineering team. Within this timeframe, the team can conduct a comprehensive DFM call and conclude with actionable steps to enhance the quote or RFQ.</p>

Read answers to top engineering questions about investment casting tolerances, wall thickness, shrink factors, and dimensional control strategies.

Casting Fit, Form, Function | Signicast Article

See frequently asked questions about the investment casting process, including design limitations, optimizing part design, alloy selection, and how to reduce costs through design for manufacturing (DFM). 

Fit, Form, Function FAQs

<h1>Maximizing Investment Casting Potential with Secondary Operations FAQs</h1><p>Secondary operations play a pivotal role in enhancing the capabilities and versatility of investment casting processes. While investment casting itself excels in creating intricate and complex geometries, the integration of secondary operations introduces several additional benefits. </p><h2>Comprehensive Machining and Casting Solutions</h2><p>Not every machine shop possesses the expertise to effectively machine a casting, just as not every investment caster is proficient in machining. Signicast recognizes this challenge and has established a dedicated internal machining team alongside our investment casting engineering team, collaborating closely during product launches and qualification process to ensure the development of the most durable and consistent end products. This collaboration enhances casting features for improved machine performance and pushes our casting capabilities to minimize machining stock, reducing time and costs.  </p><h3>Functional Modifications</h3><p>Secondary operations allow for drilling, tapping, and other processes to create functional features like holes, threads, and slots that may not be feasible during the initial casting process. These operations include straightening and coining, offering a cost-effective alternative to traditional CNC machining and providing a more economical option for controlling the position and flatness of specific features.</p><p><em>Tapping</em></p><h3>Improved Surface Finish</h3><p>Secondary operations like tumble polishing, media blasting, and more can remove surface imperfections like parting lines, flash, and minor casting defects. These processes address these issues while also enhancing the surface finish rating, reducing the need for costly manual polishing operations. By using more automated processes, they streamline production and ensure that components meet their functional requirements efficiently.</p><h3>Enhanced Dimensional Accuracy</h3><p>While investment casting offers tight tolerances, secondary machining can achieve even greater dimensional accuracy for critical features. This is especially beneficial for parts requiring precise fits or interfaces with other components.</p><p></p><p>Secondary operations serve as indispensable complements to investment casting processes, amplifying their capabilities and refining end products. From comprehensive machining solutions to functional modifications, these operations enhance dimensional accuracy, optimize surface finish, and elevate functional features. The integration between investment casting and secondary operations opens doors to endless possibilities, propelling industries forward with unparalleled quality and performance.</p><p>Sigincast helps to scale up production, exceed diverse project requirements, and maintain consistent quality standards. The company excels in seamlessly managing sudden increases in demand, giving it a competitive edge in the casting industry.</p>

Learn how Signicast's in-house services like heat treatment, finish machining, and inspection complete your investment casting to final spec.

Maximize Castings with Secondary Services | Article

See the importance of secondary operations in maximizing the potential of investment casting, highlighting how these operations improve casting capabilities and enhance the quality of finished products. 

Maximizing Investment Casting Potential with Secondary Operations

<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>

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Get a breakdown of common investment casting alloys—when to use stainless vs. tool steels, and how to balance hardness, corrosion resistance, and cost.

Investment Casting Materials Guide | Signicast Webinar

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>Lightweighting Investment Castings with Aluminum</h1><p>When most people think of investment casting, they often think of casting steel for large jet engines, but investment casting is also ideal for automotive and commercial components.  </p><p>Join Signicast’s Engineering Manager and alloy expert, as they analyze alloy offerings and discuss thin-wall casting capabilities.</p><p>Fill out the form below to download the webinar.</p>

Discover how aluminum alloys offer a winning combination of strength, machinability, and weight reduction in precision cast applications.

Aluminum Lightweighting in Casting | Signicast Webinar

This webinar discusses the use of aluminum investment casting for lightweighting in automotive and commercial components, analyzing alloy offerings and thin-wall casting capabilities. 

Lightweighting Investment Castings with Aluminum

<h1>Design Freedom with Soluble Core</h1><p>Looking to cast parts with more complexity and better performing geometries? Looking for design freedom beyond standard investment casting? Learn more about casting with soluble cores and the advantages they can offer your components during the upcoming Soluble Core webinar.</p><p>The webinar will cover:</p><ul><li>Soluble cores</li><li>Ceramic cores</li><li>Design and casting advantages</li><li>And more!</li></ul><p>Fill out the form below to get access to the webinar.</p>

See how soluble core technology enables internal cavities, undercuts, and organic shapes not possible with traditional tooling.

Soluble Core Design Freedom | Signicast Webinar

This webinar explores the advantages of soluble cores over ceramic cores in investment casting, offering design freedom and improved component performance. 

Design Freedom with Soluble Core

<h1>Converting to Investment Casting</h1><p>Whether it involves new product development or ongoing project challenges, are design problems causing roadblocks? This free webinar explores solutions investment casting offers and how others have successfully converted components to investment casting, achieving:</p><ul><li>Optimized design</li><li>Total cost reduction</li><li>Optimized throughput efficiencies</li><li>Design freedom and net shape</li></ul><p>Fill out the form below to access the video recording.</p>

Understand how switching from machining or fabrication to investment casting helps reduce weight, increase durability, and cut costs.

Casting Conversions Explained | Signicast Webinar

This free webinar discusses how investment casting can optimize design, reduce costs, improve efficiency, and offer design freedom, featuring customer success stories. 

Converting to Investment Casting

<h1>Prototyping for Production</h1><p>With many businesses looking towards additive manufacturing to solve their rapid prototyping needs, there is a rise in products that are not able to successfully transition from the drawing board to mass production. While many manufacturers are able to produce functional prototypes for testing, ensuring that these prototypes are viable and a contributing asset to a program is another challenge entirely.  </p><p>Learn how working with a team of experienced engineers can effectively streamline a project from design conception, to functional testing, all the way to a successful program launch. Topics covered will include:</p><ul><li>Solution-specific prototypes</li><li>Alloy properties and flexibility</li><li>Concurrent engineering</li><li>Vertical integration</li><li>Prototyping options</li></ul><p>If interested in prototyping or have a new project coming up, watch the webinar on-demand and learn from the team of engineers how to build effective prototypes for production.  </p><p>Fill out the form below to watch on-demand.</p><p>[Form Field]</p><p><a href="https://event.on24.com/eventRegistration/console/apollox/mainEvent?&eventid=2123791&sessionid=1&username=&partnerref=&format=fhaudio&mobile=&flashsupportedmobiledevice=&helpcenter=&key=4A9406F8D3E8944DB0F562ECBFAE7E85&newConsole=true&nxChe=true&newTabCon=true&consoleEarEventConsole=false&consoleEarCloudApi=false&text_language_id=en&playerwidth=748&playerheight=526&eventuserid=570993772&contenttype=A&mediametricsessionid=607394763&mediametricid=2993285&usercd=570993772&mode=launch">Prototypes for Production (2123791) (on24.com)</a></p>

Explore how rapid prototyping at Signicast accelerates design validation and supports seamless transition into scalable, repeatable production.

Rapid Prototyping for Casting | Signicast Webinar

Explore the challenges of transitioning prototypes to production and demonstrates how collaborating with experienced engineers can streamline the process, covering topics like solution-specific prototypes, alloy selection, concurrent engineering, vertical integration, and prototyping options. 

Prototyping for Production

<h1>Minimize Porosity Maximize Performance</h1><p>Few manufacturing processes can ensure the density of a part before it is cast. But with the right engineering expertise and state-of-the-art solidification software, minimizing porosity is not only achievable, but comes standard when Signicast’s investment casting process is utilized.  </p><p>This webinar will explore how designing the proper part with optimized gating can improve part performance during solidification.</p><p>Topics covered will include:</p><ul><li>Part geometry</li><li>Incorporating gating into part design</li><li>Gating and solidification considerations with different alloys</li><li>Value engineering and software analysis</li><li>How minimizing porosity maximizes part performance  </li></ul><p>Fill out the form below to watch on-demand.</p>

Learn how advanced gating design and process control reduce porosity in cast parts, resulting in greater consistency and mechanical integrity.

Reducing Porosity in Castings | Signicast Webinar

This webinar explores how to minimize porosity and maximize part performance in investment casting through optimized part design and gating. 

Minimize Porosity Maximize Performance

<h1>Materials Mad Science</h1><p>With investment casting, the material selection is virtually limitless. Signicast pours everything from 400 series stainless steel, to aluminum, to cobalt, to Invar and more. In fact, Signicast pours pretty much any alloy 24/7, with very few exceptions. And with so many options, Signicast wants its customers to be informed about the advantages, properties, and capabilities of each family of alloys.</p><p>Sign up for the free on-demand webinar where Signicast Metallurgist and Process Engineers will discuss popular investment casting alloy options, heat treatments, and other surface processes.</p><p>The webinar covers:</p><ul><li>Plain carbon, low alloy, and stainless steels</li><li>Aluminum alloys and treatments</li><li>Exotic alloys like cobalt, Invar, and duplex</li><li>Alloy treatments and finishing options</li><li>Material functionality, physical properties, comparable alloys, and more!</li></ul><p>Fill out the form below to watch on-demand.</p>

Join this engaging session on alloy experimentation at Signicast, where material science meets manufacturing to solve unique engineering problems.

Signicast Materials Lab | Alloy Innovation Webinar

Learn about investment casting alloy options, heat treatments, and surface processes. 

Materials Mad Science

<h1>Investment Casting and Ceramic 3D Printing</h1><p>In recent years, Signicast has been expanding its prototyping services to meet the ever-evolving needs of its growing customer base—from rapid in-house tooling to PMMA and SLA patterns for strength and design validation. Signicast understands that when seeking a fully functional prototype that will streamline the transition to mass production, clients don't want to compromise on quality for the sake of time or cost.</p><p>In recent years, Signicast has been expanding its prototyping services to meet the ever-evolving needs of its growing customer base—from rapid in-house tooling to PMMA and SLA patterns for strength and design validation. Signicast understands that when seeking a fully functional prototype that will streamline the transition to mass production, clients don't want to compromise on quality for the sake of time or cost.</p><p>With a new partnership comes access to new technologies and exciting possibilities. DDM's LAMP™ (Large Area Maskless Photopolymerization) ceramic 3D printing technology introduces advanced capabilities—including topology optimization and generative designs—for achieving the complex components clients have come to expect from Signicast, but with the convenience and shorter lead times of 3D printing.</p><p>In this webinar, Signicast's Vice President of Sales, Pete Lorenz, joins DDM founder and Chief Technology Officer, Suman Das, to discuss how this new technology can best serve customers. The webinar will cover:</p><ul><li>Investment casting and ceramic 3D printing process foundations</li><li>Metal quality and options with ceramic printing</li><li>Pros and cons of ceramic 3D printing versus 3D metal printing</li><li>Case studies</li><li>And more!</li></ul><p>Meet the speakers!</p><p>Fill out the form below to download the free on-demand webinar.</p><p>Unable to attend the webinar live? No problem!</p>

Explore how ceramic 3D printing enables faster tooling, complex shapes, and low-volume runs in investment casting applications.

Ceramic 3D Printing + Casting | Signicast Webinar

Pete Lorenz

Vice President of Sales

Suman Das

Founder and Chief Technology Office

Explore the partnership between Signicast and DDM, focusing on how DDM's LAMP™ ceramic 3D printing technology enhances Signicast's prototyping and investment casting capabilities, offering customers faster access to high-quality, complex components. 

Investment Casting and Ceramic 3D Printing

<h1>Saving cost on your component’s design</h1><p>Conversations with suppliers often start with the basics—the fit, form, and function of a new component. With many suppliers, the next step is to jump straight to quoting the component, with little time spent on optimizing the design for manufacturing. This mindset can stunt precision component projects before production even begins.</p><p>At Signicast, we believe in a value-added approach to manufacturing. This means helping to optimize component designs for greater value from the very beginning of a project. By partnering with our engineers in the early stages of part design and utilizing our “design for manufacturing” methodology, one can meet all form, fit, and function requirements while still hitting cost targets. And all it takes is a conversation.</p><p>In this webinar, Signicast's Vice President of Sales, Pete Lorenz, joins DDM founder and Chief Technology Officer, Suman Das, to discuss how this new technology can best serve customers.</p><p>In this webinar, our presenters cover:</p><ul><li>Saving cost by optimizing designs for the investment casting process</li><li>Adding value with complex features without adding cost</li><li>Design for manufacturing methodology</li><li>Part examples demonstrating both cost savings and value addition</li><li>Past case studies where we did just that!</li></ul><p>Fill out the form below to sign up for our free webinar.</p>

See how design for casting improves part performance and reduces cost by optimizing geometry, tolerances, and consolidation opportunities.

Fit, Form, Function with Casting | Signicast Webinar

Signicast's webinar emphasizes optimizing component designs for cost savings and value addition through their "design for manufacturing" approach. 

Saving Cost: Fit, Form, Function

<h1>Investment Casting Materials and Capabilities CIREX</h1><p>CIREX, a Signicast Company, is a global development partner and producer of high-quality precision investment castings. With over 80 years of experience in the “lost wax” process, CIREX delivers lightweight steel components in net-shape or near net-shape form to meet the needs of their high-tech customers.</p><p>The investment casting process has significant advantages over other manufacturing processes, including greater freedom in complex designs and material choice, leading to better-performing components. To help customers take full advantage of the investment casting process, CIREX is hosting an on-demand webinar on its investment casting capabilities, benefits, technologies, and materials.</p><p>The webinar will cover:</p><ul><li>CIREX and Signicast capabilities</li><li>Investment casting technology and process</li><li>Material options</li><li>Case studies</li><li>And more!</li></ul><p><strong>Please note that this webinar is in English. For the best experience, please register and watch the webinar on one of the supported browsers: Google Chrome, Safari, or Firefox.</strong></p><p>Fill out the form below to sign up for the on-demand webinar!</p>

Get an inside look at Signicast’s alloy options, casting sizes, tolerances, and value-added operations that support diverse industries.

Signicast Capabilities Overview | Webinar Recording

CIREX, a Signicast Company, is offering an on-demand webinar about investment casting to help customers understand its capabilities and benefits. 

Investment Casting Materials and Capabilities CIREX

<h1>Can You Cast It? Cost savings through conversion</h1><p>CNC machining is less costly for low volume runs and provides quick prototypes for proof of concept.</p><p>But, eventually, there is a crossover point is reached where investment casting is more cost-effective for larger production volumes¾and even offers a variety of prototyping processes that validate proof of concept.</p><p>Investment casting’s ability to achieve near net-shapes significantly reduces, and can often eliminate the need for machining completely. Faster turnaround for volume production is achievable with significantly less labor cost and material waste.</p><p>To learn more, join Signicast’s Sales Engineer, Josh Geib, and Prototype Manager, Zach Manvilla, as they cover:</p><ul><li>Manufacturing trends in the marketplace</li><li>When investment casting makes sense over CNC machining and other manufacturing methods</li><li>Cost-saving benefits</li><li>Conversion case studies</li><li>And more!</li></ul><p><strong>Presenters: Josh Geib, Eastern Territory Sales Engineer and Zach Manvilla, Prototype Manager</strong></p><p><strong>Fill out the form to sign up for this free webinar!</strong></p>

Find out how converting machined or welded assemblies to investment cast components can reduce manufacturing time, cost, and assembly complexity.

Converting to Investment Casting | Cost-Saving Webinar

This webinar explores the cost-saving benefits of investment casting over CNC machining for larger production volumes, highlighting its ability to reduce machining needs and labor costs. 

Can You Cast It? Cost savings through conversion

<h1>Investment Casting 101</h1><p>Looking for an effective way to produce metal components with complex shapes and sizes? The investment casting process may be the perfect solution. With investment casting, one can create almost any configuration of a desired part in a cost-effective and time-saving manner.</p><p>Investment casting is a manufacturing process in which a wax pattern is created and then coated with a ceramic slurry to create a mold. The wax is then melted out of the ceramic mold and molten metal is poured into the cavity. The molten metal solidifies and the ceramic shell is then broken or blasted off, creating a metal casting. This method has several advantages over other production processes.  </p><p>Benefits of Investment Casting:</p><ul><li>Alternative to other manufacturing processes like machining and stamping</li><li>Highly accurate parts </li><li>Produces high-quality components quickly </li><li>Economical Manufacturing process </li><li>Wide range of alloys – including bronze, steel, aluminum, iron, and brass</li></ul><p><strong>Investment Investment Casting 101</strong></p><p><strong>When: On-Demand Time: Watch Recording Now Presenters: Greg Schmidt, New Product Development Engineering at Signicast, Larry Brophy, Regional Sales Manager at Signicast</strong></p><p><strong>Fill out the form to sign up for the free webinar!</strong></p>

Learn the fundamentals of investment casting—wax patterning, shell building, casting, and finishing—in this comprehensive process overview.

Investment Casting Basics | Signicast 101 Webinar

Learn how investment casting can effectively produce complex metal components with high accuracy and quick turnaround in our on-demand webinar, "Investment Casting 101," featuring industry experts. 

Investment Casting 101

<h1>How to Decide if Investment Casting is Right for You</h1><p>No two casting projects are the same and with different projects, there are different solutions. Here are a few things to consider when deciding if the investment casting process is right for your component.</p><p>Download your free copy of <strong>Is Investment Casting Right For Your Component</strong>. In this free guide, you’ll learn how to determine if your part is right for investment casting based on:</p><ul><li>Part size</li><li>Part fit in the overall product</li><li>Part complexity, and more.</li></ul><p>And that’s just the start. Enter your details to get instant access.</p><p><strong>DOWNLOAD NOW</strong></p><p>Get your copy of "Is Investment Casting Right For Your Component.". Simply enter your details below.</p>

Robotic arm moving an investment casting mold

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Evaluate whether investment casting fits your project by exploring design complexity, cost drivers, lead time reduction, and volume flexibility.

Is Investment Casting Right for You? | Signicast

This free guide helps you determine if investment casting is suitable for your component based on factors like part size, fit, complexity, and more. 

Investment Casting: Right For You?

<h1>SOPHIA® Process</h1><p>SOPHIA®, an advanced investment casting technique offered by <a href="https://cirexfoundry.com/">CIREX Foundry</a>, the European sister company of Signicast, is gaining prominence in key sectors including aerospace, defense, and specialized applications.</p><h2>SOPHIA Process</h2><p>Employing precise post-casting cooling, SOPHIA® enhances component geometry, resulting in a finer microstructure and superior mechanical properties. Learn more about the critical role of the SOPHIA® process in this whitepaper.</p><p>Download a copy of our SOPHIA® Process whitepaper to learn:</p><ul><li>An overview of the alloys used today</li><li>Controlled cooling for controlled solidification</li><li>Solidification rate</li><li>Typical aspects of aluminium investment casting</li><li>Mechanical properties</li><li>Fatigue life</li></ul><p>A quote “from the guide”:<br /></p><p><em>"Compared to conventional investment casting, the SOPHIA® process achieves a smaller dendrite arm spacing (DAS) and a better molded eutectic. No additional modifying process of the melt necessary."</em></p><p><strong>DOWNLOAD NOW</strong></p><p><strong> Download this free whitepaper on the SOPHIA® Process by entering your details below.</strong></p>

Download this whitepaper to learn how Signicast’s SOPHIA® process drives end-to-end transparency, digital traceability, and real-time data control.

Signicast SOPHIA® Process | Digital Whitepaper

Enhanced Component Geometry and Mechanical Properties or Aerospace

SOPHIA® Process

<h1>Introducing SOPHIA®: Aluminum Investment Castings for Aerospace, Defense and Special Applications</h1><p>Signicast has been a North American leader in investment casting for decades, but our reach is global. CIREX Foundry, our European counterpart, has multiple locations across Europe, specializing in aerospace, defense, and unique investment castings for special projects.</p><p>CIREX Germany is one of only four facilities worldwide with SOPHIA® technology. We invite you to an exclusive webinar showcasing this groundbreaking aluminum investment casting process poised to reshape industries needing specialized parts.</p><p>SOPHIA® combines cutting-edge technology, precision engineering, and innovative materials. This method offers enhanced mechanical properties, reduced production times, and ultimately, superior part performance.</p><p>Join CIREX's expert engineers as they delve into the intricacies of the SOPHIA® process and its manufacturing benefits. Register now to secure your spot!</p><p><strong>Webinar Title:</strong>&nbsp;Introducing SOPHIA®: Aluminum Investment Castings for Aerospace, Defense, and Special Applications</p><p><strong>Presenters:</strong>&nbsp;Rémi Adisson and Ulrich Schneider</p>

Join Signicast experts as they discuss design strategies, materials, and testing standards for aluminum castings in mission-critical systems.

Aluminum Casting Applications | Signicast Webinar

This webinar introduces SOPHIA®, a cutting-edge aluminum investment casting process from CIREX, offering enhanced mechanical properties and reduced production times for aerospace, defense, and special applications. 

Aluminum Castings for Aerospace & Defense

<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, defense, and specialized applications, advanced innovation takes center 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 optimizes 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 aluminum is poured into a hot shell in front of the SOPHIA® chamber at around 750 degrees Celsius. The mold 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 mold, initiating solidification and further cooling the aluminum.</p><p>Post-casting, the mold 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 molding, 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 mold 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 aluminum 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 realize 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 mold 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>

Discover how Signicast delivers lightweight, high-strength aluminum castings for aerospace and defense with precision and performance assurance.

Aluminum Castings for Defense & Aerospace | Article

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

<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>

See how switching from machining or welding to investment casting can reduce costs, simplify assemblies, and improve dimensional consistency.

Converting to Casting | Signicast Whitepaper

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>Signicast Design Guide</h1><p>Investment casting has become engineers’ go-to process for its ability to deliver superior functionality across a wide range of alloys. Do you know the key factors in investment casting design that deliver the highest-performing precision components?</p><h2>Designing for Performance</h2><p>Success in investment casting means taking a more complete view of the entire design process from how the component fits into the overall product, the precise form it needs to take, and the functional efficiency it must deliver.</p><p> In this mini-guide, we’ll give you a core overview of the key elements to designing higher performing precision components with investment casting, including:</p><ul><li>Tightening tolerances</li><li>Ensuring repeatability</li><li>Tool re-design and orientation</li><li>Minimizing wall thickness, and more</li></ul><p><strong>DOWNLOAD NOW</strong></p><p><strong> Download this free whitepaper on “Designing for Performance” by entering your details below.</strong></p>

Download this guide to learn how to design parts optimized for investment casting, including draft angles, radii, wall thickness, and tooling tips.

Signicast Design Guide | Investment Casting PDF

This whitepaper provides key design tips for investment casting to achieve high-performance precision components. 

Investment Casting Design Guide

<h2><strong>Investment Castings for Defense Applications</strong></h2><p>The defense industry demands rigorous quality control for metal components, including strict documentation at every stage throughout the manufacturing process. Signicast excels in this area by adhering to the most stringent standards like NADCAP, ITAR, AS9100, and NIST. We partner with certified suppliers to ensure complete traceability and a robust, secure supply chain for our customers.</p><h2><strong>Aluminum and Stainless Steel Castings for the Defense Industry</strong></h2><p>Signicast specializes in casting a variety of alloys, with expertise in aluminum and stainless steel for defense applications.</p><ul><li><strong>Aluminum Alloys:</strong> Offer excellent strength-to-weight ratios and thin-wall casting capabilities, making them suitable for weight-sensitive applications in aircraft and satellite equipment.</li><li><strong>Stainless Steel:</strong> Ideal for high-strength, heat-resistant components like projectile launchers, and surface-mounted system housings for radar and other navigational technologies.</li></ul><p>We utilize a range of materials, including A356, A355, 201.0 (T6) aluminum, and 300 and 400 series stainless steels, to meet the diverse needs of the defense industry.</p><p>CIREX Foundry, Signicast's European sister company, specializes in investment castings for industries like aerospace and defense. They are known for their advanced SOPHIA® aluminum casting technology, which supports demanding and special projects across multiple European locations. Notably, CIREX Germany is <strong>one of just four</strong> investment casting facilities globally equipped with the advanced SOPHIA® technology.</p><h4><strong>Benefits of SOPHIA®:</strong></h4><ul><li>Enhanced mechanical properties</li><li>Reduced production timelines</li><li>Superior performance of final parts</li></ul><h2><strong>Aerospace Investment Castings</strong></h2><p>Signicast leverages soluble and ceramic core technologies to create complex, lightweight components for aerospace applications. Their <strong>fully automated</strong>, continuous-flow manufacturing ensures that high-quality, durable parts are delivered on time. From commercial jetliners to military aircrafts, they produce a wide range of components including:</p><ul><li>Interior components</li><li>Hydraulic fluid system components</li><li>Landing and breaking components</li><li>Engine components</li><li>Fuel system components</li><li>Mounted sensing systems</li><li>Fuel manifolds</li></ul><p>Visit the <a href="https://www.signicast.com/en-us/industries/commerical-aerospace" target="_self">commercial aerospace</a> and <a href="https://www.signicast.com/en-us/industries/defense" target="_self">defense</a> pages for more detail.</p><h2><strong>NADCAP Accreditation</strong></h2><p>Signicast Hartford and CIREX Germany are proud to achieve NADCAP (National Aerospace and Defense Contractors Accreditation Program) accreditation. NADCAP is an industry-driven program that unites experts from industry and government to set rigorous standards for supplier accreditation and quality assurance. This streamlined approach reduces redundant audits, improves supplier quality, and lowers costs. Through consensus-driven decisions, NADCAP ensures more thorough and technically advanced audits, benefiting both prime contractors and suppliers by promoting standardization and enhancing operational efficiency.</p><p>Learn more about Signicast's NADCAP accreditation <a href="https://www.signicast.com/en-us/certifications" target="_self">here</a>.</p><p></p>

Explore how Signicast supports defense and aerospace with certified materials, tight tolerances, and agile production under demanding specs.

Aerospace & Defense Castings | Signicast Article

This blog highlights Signicast’s advanced casting solutions for the defense and aerospace industries, emphasizing their compliance with stringent standards and their NADCAP accreditation.

Casting Solutions for Defense and Aerospace

Investment casting consists of three main stages: creating a model, forming a mold, and pouring the metal. At Signicast, we automate nearly every step of the process using advanced technology, significantly speeding up production beyond the capabilities of other manufacturers. Our innovative processes and automation allow us to efficiently go from design to delivery in 10 steps.

Investment Casting Process

<p>Signicast Hutchins is an ISO 9001:2015 certified manufacturer specializing 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.</p>

Signicast Hutchins is an ISO 9001:2015 certified manufacturer specializing 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'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.