Plaster - mix this fiber glass infused powder with hot water in order to create a plaster mold
Add a fraction of sand to the mix to help act as a natural chill for better metal quality
Mixing stations for the Plaster Mold department
Plaster Molding tables
Applying a release agent to assist in the de-molding process for plaster molds
Release agent applied to the drag pattern, ready to be blown out
Plaster has been mixed, patterns have been prepped, now it's time to make a plaster mold. Here we are using a crane to ease the process and reduce manual labor
Filling the flask with plaster to create a plaster mold
Pouring the plaster
Plaster nearing the set-up point and ready to strike off
Plaster mold just past the strike off stage. Waiting for the plaster to be at the perfect set-up/hardness point declaring it ready to de-mold
Plaster mold in the drying oven ready to be baked. Roughly 8 cope and drag molds (with sprue blocks) will fit in each oven - we currently have 6 ovens
Two drag patterns poured back to back achieving (4) parts per pour lowering cost and increasing efficiency
All (3) cores blown off and prepped, ready to be assembled. (2) cores and (1) cover core per assembly seen
Drag half of the mold housing (2) cores making a hollow rectangular part
Cover cores set in place, nails inserted and ready to be placed flush with the other assembly
Clearing out the sprue block and applying glue to the appropriate location on the cope
Assembled plaster mold with sprue block and riser
Aluminum being poured through the sprue block to control metal flow and head pressure
Visual of metal filled sprue block and risers demonstrating strong head pressure
The Plaster Mold Casting floor. Molds have all been assembled and aluminum has been poured