1. WCM Europe
Basildon
Rapid Prototype
Casting Solutions
Derek Bish

2. WCM Europe
Rapid Casting Process
Tool-less Manufacturing
• Total Design flexibility
• No two components need to be
manufactured the same allowing:
• optimum component performance
• packaging and production design validation
• dramatic reduction in both cost and lead-times

3. WCM Europe
Rapid Casting Process
Tool-less Manufacturing
• Production intent material
• No cost commitment to Hard tooling
• Parts can be used for testing and
production

4. WCM Europe
Hybrid Investment
Process Steps
• Day 1
– CAD Data (stl, iges, proE, Catia, UG, Ideas)
– Pattern build (Thermojet/Voxeljet)
• Day 2 / 3
– Add foundry methods
– Ceramic medium added
– Ceramic fired
• Day 4 / 5
– Cast
– Mould broken out
– Casting fettled and cleaned

5. WCM Europe
Hybrid Investment
Voxeljet Lost
Pattern

6. WCM Europe
Hybrid Investment
Voxeljet Lost
Pattern
•850 X 450 X 500 build platform
•PMMA with wax infiltration
•Non-thermal (uses binder)
•No support structure
•0.1mm - 0.2mm layers
•Build speed 12-48mm/hr
•Minimal ash residue
•Stable part

7. Data Pattern built
Finished Casting
Vacuum
Casting
Process
WCM Europe

8. WCM Europe
Hybrid Investment
Vacuum Casting
•300dia X 600 envelope •Up to 9 kg melt weight (Al)

9. Layer Sand Technology
Process Steps
•Day 1
•Model received
•Data Modified
•Stock added, methods, mould assembly
•Day 4 / 5
•Moulds Built (Prometal)
•Day 6 / 7
•Moulds Assembled
•Cast and Fettle
•Finished Casting
WCM Europe

10. Layer Sand Technology
Prometal Sand Printing
WCM Europe

11. Layer Sand Technology
Prometal Sand Printing
•Uses conventional sand with furan-resin binder
•1500 X 750 X 700 build platform
•Build speed 14-20 mm/hr
•Complex mould and cores
WCM Europe

12. Sand Printing Mould preparation
Mould Breakout Finished Casting
WCM Europe

13. Rapid Casting Process
• Accuracy +/- .15 Up to 125mm
• No draft / taper
• Undercuts
• Complex designs
• Thin Wall > 1mm (Hybrid Investment)
• Cast Detail
WCM Europe

14. WCM Europe
Materials
• Traditional LM25 TF
• Other Non Ferrous
• Production materials e.g. LM24
• Yellow Metals
• Cast Iron
• SG Iron
• CGi
• Stainless Steel (incl. Austenitic Grades)
• Development materials

15. WCM Europe

16. WCM Europe

17. WCM Europe