Casting using ready-made PPS models

Casting Production Process
Casting production happens much faster when the customer provides ready-made expanded polystyrene models. Such cooperation eliminates the need for numerous technological and design studies, which can reduce the time required to produce the initial product and subsequent deliveries.

Mounting Models into Blocks
For this purpose, models are assembled into blocks that have a unified gating system. One block can contain anywhere from two to one hundred models. The models are joined in the fixture by mechanical fastening or gluing. At the same time, the gating system is cast.

Models are assembled into blocks (bushes) by gluing. The blocks of models are coated with a single layer of special non-stick coating by immersion in a bath. The coated blocks are then dried in a chamber at a temperature of 40-60°C for 2-3 hours.

Coating Process with Refractory Material
The models are coated with a single layer of special non-stick coating by immersion in a bath. The coated blocks are dried in a chamber at a temperature of 40-60°C for 2-3 hours.

Mold Filling: Preparatory Stage
The molded shells are sent to the pouring area. The shells are connected to the vacuum system. A polyethylene film is placed on top of the mold. Once the vacuum pump and gas cleaning system are activated, the molding sand achieves the required strength.

The metal is poured directly into the polystyrene risers. The hot metal burns off (gasifies) the polystyrene and takes its place. The gases released are evacuated through the paint layer into the sand by the vacuum system. The metal precisely replicates the shape of the polystyrene block with the models.

Casting: Cooling Stage
The poured blocks of models cool in the sand from 5 minutes to several hours, depending on the thickness of the casting, the mass of the part, and the technical conditions specified by the technological process.

After the blocks are removed from the mold and the castings are cut from the gating system, they undergo cleaning to remove any remaining anti-stick coating.