Aluminium can be cast using several different methods, the most common are high pressure die casting and sand casting. Ventana Hackås AB (VHs) provides Plaster mould casting and Rapid Casting. These are two less known complements to the above two methods. Plaster mould and Rapid Casting are suitable for volumes between approx. 1 to 500 pcs/year. Rapid Casting is a method for the production of prototypes based on a lost pattern produced by Selective Laser Sintering, SLS. The SLS-pattern is embedded into a plaster mould, which after being dried, is heated to a temperature high enough to completely burn away the pattern before the form is being filled with molten aluminium.
High pressure die casting requires larger series (min. 1000 pcs/year) due to relatively costly dies and high set-up costs. Hand-moulded sand casting is often used for larger components, with high demands on strength and where lower precision and surface finish can be tolerated. When a company requires aluminium castings with high surface finish and close tolerances in volumes up to approx. 500 pcs/year then Precision Castings according to the Plaster mould or Rapid Casting methods can be suitable alternatives.
Casting simulation of the metal flow and solidification are important tools in our process planning. We use the NowaFlow&Solid CV. software. We are of the opinion that simulation safeguards the optimal design of the gating system which in turn is a decisive factor for the performance of the end product. Sometimes the simulation results generate suggestions for changes in the product design.