As one of the well-renowned foundries in Springville, we at MACA supply own two full-time pattern makers with the expertise to produce quality patterns, as well as repair and rig existing patterns. Our well-qualified engineers are capable of producing high-quality patterns that can make thousands of molds.
Pattern making is the process of making patterns of metals. Patterns are nothing but the models of the materials to be cast. They shape the poured metals into the desired shapes. They can also impressions of the molds to let the metal solidify into the desired pattern shape.
At MACA supply, we follow a well-organized pattern making process that can give us accurate molding designs as requested by our clients. We strongly believe that patternmaking is the first and the most essential step of the metal casting process. Below are a few patterning allowances we consider while building a pattern.
Once the mold is formed, the pattern has to be removed from the mold without disturbing its shape or size. To do this we incorporate a draft taper that facilitates pattern removal. The accurate angle of the draft depends upon the complexity of the pattern, the mold, and the surface type. To ensure that the draft gets the proper removal angle we take care that the pattern, mold, and surface are up to the mark.
It is a known fact that metals expand on heating and contract on cooling. Being one of the best patterning foundries, we make sure that the patterns we design are made a little larger than the specified dimensions. Depending on the metal cast, we make different precise shrinkage allowances.
At times, when the expected cooling distortion of the patterns does not happen we intentionally disturb them to get it done.
Sometimes, the metal castings might require machining to finish them; patterns with machining finish are usually subjected to material loss. To compensate for it, we include excess material predicting the amount of material lost in the machining stage.
The pouring cup is nothing but a tapered entry into the mold. It helps in controlling the flow of metal and also captures slag during pouring. It helps in maintaining the appropriate flow rate of the metal during casting.
Also known as down-prue, Sprue is the main channel into the mold that is used to fill casting into the mold.
Runners are the channels that can allow the metals to flow from one area to another inside the mold area.
Gates are the materials through which mold slows to fill in the mold cavity. Smaller gates are used to solidify low cooling castings and larger gates are used to solidify high cooling castings. We make sure that the gates are properly placed to promote high directional solidification of the casting process.
The riser is a component that is used to prevent shrinkage cavities.
We choose the pattern materials like metal, wood, plastics, and wax depending on the volume and castings process used. The patterns we design may vary in size and shape. Below are a few common pattern types we use at our foundry.
These patterns are usually made of wood. These are single representations of the casting to be produced and can be used to mold only a single casting at a time. These types of patterns are molded by cutting feeding systems of castings into sand by hand. These patterns are also split into halves at times to carry on the molding. Loose piece patterns are best suited to produce few castings.
The gated patterns are often used to enhance the reproducibility of the molds and also accelerate the quality of the casting process. These are capable of incorporating a gating and running system along with the patterns produced.
We use these patterns to cast large circular ring-shaped products. To prepare the final product using this type of pattern, the metal is first to mold at one place and rotated in the next portion repeatedly till it is done.
The skeletal patterns are generally in the casting of heavy metal objects. The patterns look like a rib cage and are used in designing the outer and inner surface structures of huge metal parts.
We at MACA supply, recommend clients to give us complete details of the product along with the description to design the patterns as per the requirements.
The shape and size estimates of the parts to be designed are required to make the required patterns. Based on the given details we shall design little larger patterns to deliver the final products with exact size.
The part functionalities are to be clearly understood by both the parties before starting the project. This can ensure that the final product delivered is of superior quality.
Give us the expected annual usage, production quantities, and the expected lifespan of the product before we start designing the patterns.
Reach out to all our queries regarding the patterning designs and get a quote of the estimated price based on the weight, type, shape, and size of the required material. We are just a call away. Dial us to collaborate with us for your pattern designing, molding, and casting requirements.