Design for Investment Casting Process

The goal of Modulus Metal is to work with our clients to create premium investment cast components with increased performance and durability. This necessitates an investment casting that has a robust mechanical design, reliable production controls, takes into account market economic factors, and fosters open communication between all parties.

The cost of the final product will rise with tighter dimensional tolerances and inspection requirements in any manufacturing process. Thanks to Modulus Metal’s early engagement and help, customers may be able to overcome issues with standard casting tolerance. Technology and innovation provide complete as-cast conformity with specifications, on-time delivery, and the lowest total cost. The most important piece of advise is to use Modulus Metal from the beginning of the design process.

Investment Casting Design Parameters:


Weight and Size: Since both part size and weight have an impact on mold capacity, they are the most important elements in determining part cost. The cost of the part decreases as more parts may be produced on a mold. To minimize part weight, our design team will work with you to eliminate any extra bulk.

Quantity of gates: A portion should, wherever feasible, be created to be fed by a single gate. This will often increase the number of pieces produced per mold and aid in lowering the pour weight each mold. By supplying a directed solidification pattern, single gate feeding also improves the dimensional stability of a particular component.

Castability: The engineers working for Modulus Metal will suggest design improvements to reduce the piece price if a design has elements that would increase scrap or rework rates (and piece price).

Tooling: To assure consistent, high-quality design and manufacture of the wax injection die, which is often guaranteed for the life of the component, Modulus Metal uses a system of tooling standards. We provide manual, semi-automatic, and fully automatic tools in various forms. Additionally, one of our collapsible, soluble, or ceramic core inserts must be used in combinations where metal cores in tooling cannot be drawn due to undercuts or complex internal forms.

Wall Thickness: Corner radii and minimum wall thickness are determined by the part’s size and configuration. Walls in small investment castings may be cast to a thickness of 0.08mm. Depending on the component shape, medium to large castings need walls that range from 1.3mm to 2.54 mm

Tolerances: Excellent reproducibility is possible with investment casting. When a single point location is regularly measured, the as-cast method has a capacity of +/- three standard deviations, which is generally +/-0.08 to +/-0.10 per mm. However, part configuration has a significant impact on tolerance capacity. In comparison to non-symmetric, non-uniform structures, symmetric geometries with uniform wall sections will harden with far less variance and distortion.

Additional design factors consist of: Straightness and flatness, linear and positional tolerance, Orientation, Profile, Texture of the surface, Radii, Gate witness tolerances, holes

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