Graphite Mold Casting
Graphite Permanent Molding is a niche process used for casting zinc-aluminum alloy parts. The graphite permanent mold system offers a lower cost tooling alternative than die casting. Tooling is computer generated and fed directly to our high speed CNC Mills, where the graphite tool is cut. The speed in which graphite can be machined allows for rapid engineering changes, often in hours or days, as opposed to weeks or months like some alternative methods. These features allow the graphite system to exceed the potential of sand casting and to produce parts that rival those produced in a die-casting mold at a reasonable premium piece part cost.
Graphite is extremely stable: it will not warp, twist or check when molten metal is introduced. Parts can be cast with higher accuracy than sand processes. The Graphite Process produces castings with a surface finish better than 125 RMS. Graphite can be stored indefinitely without changing shape, rusting, oxidizing or deteriorating in any way. This process will deliver high tolerances, cost effectiveness and repeatability.
Advantages include:
- Cast precision to +/-.005 which reduces secondary machining
- Cast surface finish of 125 RMS or better
- Tooling cost savings is as high as 50% to 75% over die castings and other cast methods
- Excellent detailing and flatness
- Tooling lead times of only 3-6 weeks
