Tool design is crucial to achieving the perfect casting and the perfect coating. We apply state-of-the-art computational 3D fluid dynamics analysis to optimise the positioning of the inflow and outflow gates – vital to being able to achieve the correct filling speed. This is key to maintaining a low porosity casting. In order to ensure a perfect finish, the surface coating needs a degree of texture to grip on to, so the tool must be machined to just the right extent – too rough and the finished product will have blemishes, too smooth and the coating will not adhere correctly.
Our advice on tool design can save you a small fortune, so we recommend involving us as early in the process as possible.
Our engineers are unrivalled in their technical abilities. We design every tool to the highest specification so the castings will be suitable for the most difficult surface coatings. We use electrode spark erosion techniques to create the tool and then machine the surface to perfection – taking into account the application for which the casting is designed – as one or two microns can make a material difference to the finished product.
Unit inserts offer a cost-effective alternative to manufacturing an entire tool. Because only an insert, ejector plate and cavity detail are required, they are faster to make and production costs are lower. For smaller production runs this can be ideal.
Unit tools need a bolster in order to be used, and because we’ve been in business for over 45 years we offer our clients a huge range to choose from. Consulting with us early in the design stage allows us to match your new products to existing bolsters with the requisite slides and connections. This achieves substantial cost savings.
However, for sizeable production runs or castings that are either large (over 30g as a guideline) or require a high quality finish, a full tool is generally required.