At PPCP, we are a highly customer-centric investment casting foundry, which is why we offer extensive drawing/mold file flexibility. Our objective is to make submissions easy and cost effective for our customers. We understand that a wide range of formats are used at different companies, so we accept the following:
For assistance, give us a call at 717-273-3338.
To produce top-quality precision cast parts that meet or exceed customer expectations, PPCP is deeply committed to achieving or surpassing investment casting industry standards. That is why we subscribe to the guidelines of highly respected industry groups, including:
American National Standards Institute (ANSI) www.ansi.org
ASTM International www.astm.org
American Welding Society (AWS) www.aws.org
Aerospace Material Specifications (AMS) In addition, PPCP maintains rigid quality assurance processes to ensure that all the parts we cast deliver the performance and value our customers expect.
Have you ever wondered what PED compliance is as related to investment casting? It is actually quite simple, yet very important. PED is an acronym for Pressure Equipment Directive, and compliance is required in the European Union (EU). Valves, pumps, and other pressure-bearing equipment utilized in the EU must comply with strict production standards. To demonstrate compliance, the equipment must have the CE mark prominently displayed. PPCP is certified PED through Hartford Steam Boiler International and is audited regularly to ensure strict compliance. View PED. http://ppcpinc.com/pressure-equipment-directive-ped
If you are considering processes for producing your precision cast parts, you may find it helpful to take a look at PPCP’s investment casting downloads on our website, www.ppcpinc.com. Included are:
PPCP Investment Casting Process To answer further questions and assist you in getting started, give us a call at 717-273-3338.
A common question customers ask PPCP is “What are investment casting material surcharges and why do they exist?” The short answer is they are a good way to address volatile alloy costs. To simplify the pricing process, PPCP has two-component pricings. The first part is the cost of the production process. That includes everything other than the alloy expense. Unlike alloys, the process price does not often change. Alloys, however, regularly change in cost, so PPCP includes a material surcharge that fluctuates with the alloy market price. You can view material surcharges on the PPCP website, here: https://ppcpinc.com/metal-and-energy-surcharge-information/
If you need to produce precision cast complex parts, investment casting is an ideal option. Investment casting can accommodate complex geometries that would be painstaking or unachievable with other production processes. The molds used in investment casting allow molten alloys to flow through intricate, continuous passages. When the casting cools and the mold is knocked off, the resulting part is a single, near-net-shape unit. This greatly reduces or eliminates the often extensive machining and finishing work required with other processes. It saves time and cost, while decreasing material waste.
Most manufacturers are under increasing pressure to produce products faster and more economically, which is why you should know about investment casting rapid prototyping benefits. Constantly advancing 3D printing capabilities and freeform fabrication make rapid prototyping an economical, time-saving option to conventional prototype fabrication. It utilizes cutting-edge computer technology to produce extremely accurate 3D models. It prints a great many layers of prototyping material, resulting in near-perfect geometries, quickly and economically. Read about PPCP’s rapid prototyping. http://ppcpinc.com/capabilities-services/value-added-services
The final two steps of investment casting are testing and inspection, followed by packing and shipping. Thorough testing, using cutting-edge instruments and processes, and detailed part inspections are critical for quality assurance. Tests such as spectrographic analysis, photomicrographic analysis, ultrasonic testing, OE spectroscopy, corrosion testing, radiographic testing (RT) and others are utilized. Finally, the finished castings are securely packaged and shipped to the customer as specified.
The next two steps of investment casting are knockout and finishing. After the castings have cooled, the ceramic shells are broken off using powerful, jackhammer-like tools. It is a very loud and violent part of the process. The castings then go to the finishing department, where any excess metal is removed, the surfaces are polished and finished as specified, and then are heat-treated to ensure the parts have the right properties. Heat-treating can strengthen the parts, improve their elasticity and more.
The next three steps of investment casting are dipping and coating, de-waxing and firing, and casting. The finished sprue is coated with multiple layers of ceramic and stucco. This can be done by hand or robotically. The result is a hard shell around the wax on the sprue, creating the casting molds. Next, the sprue is flash fired to melt and remove the wax, leaving only the molds, which are heated to 1,800 degrees to prepare it for receiving molten alloys. Next, the molds are placed on a sand bed and are filled with molten alloy that can be as hot as 3,000 degrees or more. After pouring is complete, the molds and metal are allowed to cool.
While there is a total of nine important steps, the first two steps of investment casting are critical to the quality of finished parts. The first is tooling and pattern making. A very high-quality tool is made that has a specified shape or geometry. While this tool requires a significant investment, it will last a long time and result in many parts. Wax is injected into the tool, creating a pattern or prototype of desired parts. The second step is pattern assembly. Rather than make one casting at a time, multiple patterns are mounted together on a sprue. Channels are created that allow molten alloys to be poured into all the patterns at once.
If you are like most manufacturers, you would be delighted to eliminate one of your production headaches, so you should consider the precision cast satisfaction you will enjoy with the investment casting process. In a large majority of cases, investment casting produces higher quality, greater consistency, fewer faulty parts, less need for finishing work, more flexibility, superior cost-effectiveness and other advantages over other processes. Perhaps most importantly, it can increase your bottom line and decrease your stress level, which is an invaluable benefit.
Determining the true cost of parts is more complex than identifying the per-unit direct expense, which is why the precision cast cost-effectiveness of investment casting is an excellent choice for many parts and applications. In many cases the up-front tooling expense of investment casting is higher than other processes, but that is not the whole story. When you take into account other factors, like less machining and finishing, fewer faulty parts, greater consistency and reliability, longer tooling life and more, investment casting can be more cost-effective in the long run and deliver a higher return on your investment.
Complex manufacturing needs that require a versatile production process can often be met by the precision cast flexibility of investment casting. In addition to being able to accommodate intricate geometries and challenging designs, investment casting can utilize a wide range of alloys, from traditional metals like iron and copper to specialized alloys including duplex alloys, cobalt, monels, and many others. Custom alloys can also be fine-tuned to meet the exact specifications required for unique requirements, achieving maximum versatility.
Manufacturers that produce components for critical functions often opt for the precision cast performance investment casting can deliver. The investment casting process can achieve the most exacting specifications and rigorous requirements, making it ideal for applications where failure is not an option, such as medical instruments, military equipment, transportation components, and many others. It reliably and consistently produces precise cast parts over the longest, most challenging production runs.
The start of the new year is a great time to take a look at your manufacturing process and consider precision cast quality with investment casting and PPCP. If producing top quality components is a high priority for you, investment casting’s near-net-shape process could be the perfect fit. Parts come out of the mold almost exactly to spec and require little or no machining and finishing work. That ensures maximum quality and cost-effectiveness for your parts runs.
Manufacturers rely on investment casting quality for an extremely wide range of parts, applications, and industries. Precision cast parts made through investment casting are among the highest quality in the casting industry. Investment casting’s near-net-shape process is a key reason for this capability. Parts often come out of the mold ready to go, with little or no finishing work. It also ensures that every part will meet the same high standards and specifications, even through long runs of challenging designs. When produced by a top-notch, experienced foundry, investment casting quality can’t be beat.
Investment casting consistency is one of its most important advantages for manufacturers who need to produce parts for vital functions with very tight specifications. It can achieve excellent consistency because its process employs precise tooling, wax patterns, and ceramic molds that deliver virtually identical parts, unit after unit. It can achieve extremely tight tolerances that most other processes cannot accommodate. Investment casting also requires very little, if any, machining and finishing work, which can add flaws and inconsistencies.
When choosing a process for your precision cast parts, investment casting versatility can be a major factor. Investment casting can accommodate a virtually limitless list of alloys from traditional, commonly used metals to highly specialized alloys, designed to meet rigorous specifications. It can also produce very small to very large sizes with complex geometries and designs. Whether you need parts for pumps, valves, compressors, railways, food applications, medical equipment, or almost any other industry, investment casting can deliver for you.
As we enter the new year, we all want 2022 to bring us great things. What can we do to make that happen? Investment casting is a good start if you’re a manufacturer who requires precision cast parts. If you have been using other processes to produce your components, now is an excellent time to take a good look at investment casting. It offers an array of advantages, from versatility and precision to quality cost-effectiveness. It is important to remember that top quality investment casting requires expert, experienced foundry professionals. PPCP is a good place to start.
It is common for manufacturers to choose investment casting for complex parts. It is an excellent option for components with geometries that would be difficult or even impossible to achieve with other processes. In investment casting, molten alloys are poured into molds that are nearly the exact shape of the desired castings. This enables the alloys to freely flow into complex geometries. It then cools into one continuous piece, requiring very little or no machining. Other processes often require extensive finishing work and still get an inferior result.
To achieve extremely high-quality part surfaces, many companies choose investment casting for excellent finishes. Investment casting’s near-net-shape process utilizes precision molds that have virtually flawless internal surfaces. As the molten alloys poured into the molds cool and solidify, the parts assume the same quality and characteristics of the mold surface. Finishing work and machining are often unnecessary, which saves cost and time while significantly reducing flaws.
Savvy manufacturers often choose investment casting for critical functions when component performance is essential. For a wide variety of industries, highly reliable parts are necessary to ensure proper functioning and, in some cases, the safety of life and property. Investment casting can accommodate a wide variety of traditional and specialized alloys that may be needed to achieve critical functions. In addition, it nearly eliminates shrinkage, porosity, and other defects that can compromise castings. The high degree of repeatability that investment casting offers ensures quality and reliability over full part runs.
Many manufacturers choose investment casting for less waste when making precision cast parts. It is an excellent option for a broad array of parts and components in virtually any industry. The near-net-shape production process utilized in investment casting produces castings that are extremely close to the exact geometries specified for the finished parts. As a result, there is very little or no machining and finishing work required, which can significantly reduce waste. It also saves cost while producing a more sustainable product.
By its nature, the railway industry creates one of the most punishing, high-demand environments for its components, which is why precision casting is ideal for railway. Investment casting can produce the top-quality, rugged, high-performance parts that are essential for a vital transportation and distribution channel. It has the flexibility and capabilities to meet railway’s widely varying needs, from creating the comfort and appeal of passenger service to the heavy duty, harsh requirements of freight lines. Investment casting is able to produce very small to large parts made from an extensive array of alloys, which can achieve special characteristics and performance levels. It delivers the quality, dependability, and cost effectiveness that help keep the railway industry on track.
Industries that require exacting process control often rely on precision casting for controls and instrumentation. To meet the very high levels of quality, dependability, and accuracy that are needed while accommodating complex design and production needs, many manufacturers utilize investment casting. The near-net-shape process can precisely produce highly intricate parts with minute tolerances. It can also achieve exceptional finishes, with little or no machining, which reduces cost and production time. Investment casting is an excellent process for producing controls and instrumentation.
Precision casting for specialized hardware is the preferred choice for a wide variety of industries and applications. Investment casting can efficiently and economically produce parts that have unique and often challenging characteristics and specifications. From architecture and construction to transportation, energy, and numerous others, investment casting offers the capabilities, flexibility, performance, and reliability to produce parts of almost any size and geometry. It can also employ many specialized alloys to produce necessary characteristic for endless needs.
Utilizing precision casting for gas and air compressors offers manufacturers the very high degrees of precision, reliability, and performance that are essential for these components. Investment casting can meet and exceed expectations by achieving the precise specifications and minimal tolerances that are essential in compressor manufacturing. The extreme accuracy of molds used in investment casting can successfully accommodate challenging engineering specs, while minimizing the need for finishing and machining, which also saves time and cost.
To produce the quality and precision they required, many manufacturers utilize precision casting for valve production. Investment casting is an excellent choice for a broad range of valve components and applications. The complexity and exacting specifications of many valves, as well as the need for consistency and reliability, often make investment casting the preferred process. The precision and flexibility of the near-net-shape process can accommodate challenging designs and geometries, while delivering the performance manufacturers need. It is also a cost-effective option, particularly for long and repeat runs.
To ensure proper quality, performance, and specifications, essential foundry capabilities include non-destructive testing. Integral to investment casting best practices are high-tech inspection and testing. These procedures can confirm that all standards and expectations are being met in the process or identify issues that must be addressed. Deficiencies can be observed that may otherwise be invisible to the naked eye. Many such issues are deep within the structure of the parts. Among the many non-destructive tests that can be used are spectrographic analysis, ultrasonic testing, corrosion testing, radiographic testing (RT), mechanical testing, and magnetic particle inspection (MPI), to name just a few.
One of the essential foundry capabilities is dipping and coating. In investment casting, dipping and coating refer to the creation of the molds utilized to make the castings. Multiple wax patterns are connected to a structure called a sprue. The sprue unit is then repeatedly dipped into vats of stucco and ceramic, forming a hard shell. After the wax is melted away, molten alloy is poured into the molds. The selection of the dipping material and the actual coating process are critical to the quality and performance of the finished parts. Foundry staff must be knowledgeable and experienced to get optimal results.
One of the most essential foundry capabilities is alloy management. To meet the wide array of manufacturer needs and specifications, a foundry must be able to utilize a variety of specialized alloys, as well as common metals, such as iron, steel, and bronze. Foundries that have metallurgists on staff can manage the usage of alloys from start to finish during the investment casting process. Ensuring the right proportions of individual metals, monitoring the quality of castings during the process, making in-process adjustments, and performing testing to make sure specifications and performance standards have been met are crucial. Effective alloy management is essential.
When choosing a partner to produce your parts, it should have essential foundry capabilities, including investment casting expertise. While the investment casting process may seem straightforward at first glance, it is actually quite complex and nuanced. Each step in the process requires careful planning, monitoring, and execution. It is essential that foundry staff have the technical knowledge to ensure that the process is optimized and that all specifications are achieved. It starts with the design and engineering of the tooling and continues through producing the right alloys, creating the molds, pouring the molten alloys, performing finishing work, and many other aspects of the investment casting process.
If you have questions about precision cast parts or the investment casting process, PPCP can provide the answers. Even for people in the manufacturing business, understanding all the details and nuances of investment casting can be difficult. It can also be hard to know whether it is the right process for your specific parts and applications. PPCP’s expert casting professionals can answer your questions and help you choose the right options for your unique needs and preferences. You can submit your question on the PPCP website (https://ppcpinc.com ) or call 717-273-3338. Connect now for answers and assistance.
When you are in need of top-quality castings for virtually any manufacturing application, send your precision cast parts RFQ to PPCP. In addition to getting a competitive price quote, you will receive the assistance of an industry leading team of investment casting professionals with extensive industry experience and foundry knowledge. Submitting an RFQ to PPCP is fast and simple. It can be done on the PPCP website at the top of the page at your convenience. Provide the required information, and attach your specifications and/or design file, if they exist, and PPCP will promptly respond. You will be well on your way to getting the excellent precision cast parts you require for your application.
An integral and crucial part of making high-quality, dependable precision cast parts is the right testing for investment castings. It is an essential quality assurance component that can confirm compliance with specifications and identify potential faults that would otherwise go unseen. Non-destructive testing can reveal a wide variety of invisible issues so that the foundry team can make adjustments to ensure first-rate castings. Among these tests are Radiographic Testing (RT), Magnetic Particle Inspection (MPI) and Liquid Penetrant Inspection (LPI), to name a few. It is important to confirm that your foundry has appropriate testing capabilities to make sure that you receive the quality, accuracy, and performance you need.
A key component of producing exceptional precision cast parts is investment casting tooling. While other casting processes have their own benefits for some applications, investment casting is often the optimal choice when taking all factors into consideration. Tooling is the first step in achieving such excellent results. The process begins with the design and production of a split aluminum tool, also called a die. The quality and accuracy of this tool is essential because it defines the geometry and characteristics of every casting produced. The tool creates wax patterns that are layered with ceramic and stucco material, which produce molds for the castings. The castings are only as good as the tooling. That is one of the reasons why it is cost effective in the long term to invest somewhat more upfront for the tooling than in some other processes. Manufacturers typically find that the overall ROI is worth the cost.
Due primarily to the employment of its “near-net-shape” process, investment casting reduces waste when producing an endless array of parts. Because investment castings typically do not need much or any machining and finishing work, only a relatively small amount of material is wasted. This can be quite significant in long runs and when costly alloys are specified. Also, it is common to have fewer rejected parts with investment casting, because of its high quality, precision and repeatability. An added plus is the reduced waste supports a commitment to sustainability.
Investment casting is flexible, which makes it the ideal process for many diverse needs. It has the versatility to accommodate complex geometries and challenging designs. It can also produce an array of surface finishes to meet manufacturers’ needs and specifications. In addition, investment casting can utilize numerous different alloys, from standard, mainstream metals to highly specialized, custom alloys. These and many other characteristics of investment casting make it the go-to process for many manufacturers in a broad range of industries.
While it is true that in some cases it can be more expensive, when you consider all of direct and indirect costs, investment casting reduces cost in many applications. This is especially true for long and repetitive runs, where the initial tooling investment can be allocated over many parts, lowering the cost per casting. It is also important to take into account the quality and consistency of investment casting. There is often a significantly smaller amount of rejected and off-spec parts. In addition, investment castings typically require very little or no machining and finishing, which saves on labor and waste.
Investment casting delivers consistency that is essential for a wide array of components and applications, from pumps and valves to medical instruments, precisions tools and military equipment. Investment casting’s “near-net-shape” process produces parts that are very close to the desired shape and specifications, greatly reducing or even eliminating the need for manual machining and finishing work. This helps ensure that every part is virtually identical at the end of the investment casting process. The manufacturer saves time, money and production headaches.
For many parts and applications, investment casting improves quality over other processes. This is largely attributable to the “near-net-shape” process investment casting utilizes. Extremely accurate tooling creates wax patterns that form ceramic shells which can achieve even the most challenging specifications. Molten alloys are poured into these molds, allowing the metal to duplicate the original prototype with accuracy other processes are typically unable to match. In addition, investment casting can produce exceptional surface finish quality that tends to have fewer defects and flaws. The outcome is the quality many manufacturers require.
Investment casting can effectively deliver top-quality, specialized precision cast parts for railways and the transportation industry. Because railways provide critical distribution and transportation services that are vital to our economy and security, it requires highly reliable, cost-effective parts and components for its equipment. Investment casting has the capabilities and flexibility necessary to meet railway’s needs for both freight and passenger lines. It can produce an extensive variety of parts, up to two hundred and fifty pounds, made of a wide array of specialized alloys to achieve necessary characteristics. Investment casting helps railway move America.
Investment casting can produce the precision cast parts that are vital for military & defense components and applications. The highest levels of performance and reliability can be achieved in even the most complex designs, while maintaining near total consistency. Miniscule tolerances, excellent surface finishes and special properties and characteristics are also delivered by investment casting. It is an ideal process for the critical missions and needs of military and defense applications.
The need for ultra-specialized, extremely reliable equipment and instruments makes investment casting an excellent choice for making precision cast parts for medical applications. Both medical and dental procedures and treatments require near perfect accuracy, exceptional quality and unfaltering performance. Investment casting’s near-net-shape process can deliver these characteristics with extreme consistency. Its ability to utilize a virtually unlimited range of specialized alloys is also a crucial success factor. Effectively producing these vital components is truly a lifesaving responsibility.
Investment casting is an ideal process for making precision cast parts for mining, oil & gas applications. Its flexibility, consistency and reliability make it a cost-effective way to produce top-quality components that can stand up to this punishing industry. It can cast a nearly unlimited array of part designs and accommodate an extensive variety of common and specialized alloys. This makes it possible to achieve the specific properties needed in the mining, oil & gas industry. In addition, investment casting can produce part sizes from a few ounces up to two hundred and fifty pounds, which can be required in these applications.
A foundry with the experience and expertise to effectively work with aluminum alloys is a critical investment casting valuable resource for many companies. Aluminum is a high-value metal that offers numerous beneficial properties, including being durable and lightweight, malleable, highly workable, non-corrosive and an excellent conductor of electricity, just to name a few. It is utilized in numerous alloys that can accommodate diverse applications and requirements, achieving demanding specifications and performance. It can be ideal for diverse parts and components, such as valves, pumps and a vast array of industrial and commercial applications. As a result of investment casting’s near-net-shape process, there is little or no material waste, which is especially important with more costly alloys like aluminum.
Flexibility and versatility create an important investment casting valuable resource for a variety of manufacturers. Many aspects of the investment casting process make it an excellent choice for a wide variety of parts, applications and needs. This is especially important for manufacturers who wish to produce multiple parts at one foundry. Parts can be produced from a nearly limitless array of common and specialty alloys. Their sizes can range from a few ounces to 250 pounds or more. Surface quality can range from standard, economical grade to ultra-high quality for specialized needs. Parts can be produced to meet extremely tight tolerances, even with complex geometries. Investment casting also offers design flexibility for production efficiency, little or no post-casting finishing, minimal waste and much more.
An investment casting valuable resource that can offer significant benefits for manufacturers is PPCP’s Rapid Prototyping. This 3D printing or Free-Form Fabrication process creates 3D models of parts in materials that enable manufacturers to cast, test and study products and their specifications, without producing an actual part. Rapid Prototyping makes it possible to make a test copy of a product for a small fraction of the cost necessary to fabricate the investment cast tooling needed to produce the desired part. In addition, the lower cost and lead times make it practical to produce multiple prototypes versions with different specifications for comparison. Typically, it takes just a few days to produce a Rapid Prototype part.
To ensure consistent, on-time delivery of the parts manufacturers need, PPCP offers its Zero Days Lead Time Stocking Program, another investment casting valuable resource. This consignment/stocking program makes it possible for customers to have a steady flow of key components, paying for them when they are used instead of than when they are shipped. The most important benefits of this program are time saving, to make sure production is not delayed or interrupted, and lower expenses, without tying up funds with premature payments. Zero Days Lead Time Stocking offer excellent just-in-time value.
