Aluminum & Zinc Aluminum Castings - Patternmaking - Sand Casting - No Bake (Air Set) Sand Casting - Permanent Mold - Rubber Plaster Mold (RPM) - CNC Machining
General Foundry
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PATTERNMAKING       PRECISION SAND CASTING       NO BAKE SAND CASTING       RUBBER PLASTER MOLD       PERMANENT MOLD       CNC MACHINING

To get a copy of our Design Guide, or to Send Files for Quotation, please go to Get Quotes/Send Files page.

PATTERNMAKING

General Foundry Service's niche is making "Thin-Walled", "Smooth Surface" Castings per our customers requirements.

The Patternmaker's task is to translate engineering drawings into foundry tooling so that an accurate casting (with finish allowance) will be produced. Patterns are highly specialized, full-size models of the finished casting.

If you have a complex casting, we may use cores to create hollow features or side features that may not be easily produced in a more simple mold configuration.

Core boxes are used to produce special sand and resin binder mixes that are packed in the core box to establish their size and shape. This core is then "set" into the sand mold to restrict metal from flowing into areas such as cavities inside the casting, once the mold is closed and metal is poured.

Our skilled craftsmen have years of experience in making patterns to exacting tolerances in wood or plastic via traditional methods.

The pattern on the right is a fabricated wood/plastic pattern that is primed and sanded to a smooth finish.

Another option is to create patterns in plastic, using your CAD generated data through CNC Machining in a "subtractive" process.

The pattern to the right is a machined pattern from polyurethane foam board. It will be coated with a primer then sanded to a smooth finish.

We can create patterns in plastic, using your CAD generated data through StereoLithography. SLA patterns are made in a method of rapid prototyping which converts 3-D CAD data into a series of very thin slices or cross sections and uses a laser-generated ultraviolet light beam to trace each layer onto the surface of a vat of liquid polymer. As the laser hits the photopolymer it is catalyzed, subsequently forming, hardening and bonding each layer until the complete, full-size pattern is formed. The SLA pattern will be coated with a primer then sanded to a smooth finish.

Nearly any geometry imaginable can be created with this "additive" process including closed or trapped volumes. An advantage over machining is that there are no additional set-ups required to form the "underside" of the part and no radius allowance is required for square corners. Additionally patterns of high complexity can be created with a high degree of accuracy.

Once the patterns are created and coated, the visible difference is hard to see.


We work with our customers to select the most economical way to produce the highest quality pattern within the desired delivery schedule.

Please contact General Foundry Service to discuss patternmaking and our design recommendations.

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