Leicester, UK – A new mass casting service from Base Materials is designed to ensure cast tools and models are as close to the final shape and size as possible, reducing the amount of post-production machining required.
The process relies on using one of its low-density polyurethanes to create a negative mould for the tool. This mould is then used to cast the near-net-shape tool in a range of different materials, with densities from 600 to 1700kg/m3.
Mass casting leaves no visible bond or lines on the surface, but near-net-shape casting, using a mould to cast it close to the final form, also eliminates material wastage and reduces downstream processing costs.
“We are keen to provide an alternative solution to complement our existing composite tooling board materials that are blocked up and milled to shape using a CNC machine,” said John Miller, the company’s MD. “Casting a tool or model in one single piece with no witness or bond lines can be a key factor in some automotive and aerospace applications, where a high aesthetic finish is essential.”