Full Mold casting Services
Frigate uses Full Mold Casting with expanded polystyrene for complex geometries. We ensure precise mold burnout, achieving accurate tolerances and minimal thermal distortion.
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Advantages of Full Mold casting Services
Thermal Stability
The casting process minimizes thermal expansion, allowing consistent properties across the entire casting, which is crucial for high-performance applications.
No Draft Angles Required
Patterns can be made without draft angles, allowing for sharper details and reducing the complexity of the pattern-making process.
Fast Production Cycles
This method allows quick pattern production and streamlined casting, making it ideal for short lead times and rapid prototyping.
Lower Risk of Defects
By eliminating parting lines typical in traditional molds, Full Mold Casting reduces the occurrence of casting defects like flash or mismatches.
Advanced Solutions with Custom Full Mold Casting Services
Custom Full Mold Casting offers precise manufacturing for intricate and complex designs. This method utilizes expendable polystyrene patterns to achieve tight tolerances and sharp details. It reduces tooling costs and accelerates production timelines, making it ideal for high-precision applications. The process ensures minimal thermal distortion, resulting in consistent dimensional accuracy and superior surface finishes. Full Mold Casting is compatible with various alloys, accommodating diverse material requirements. The method eliminates parting lines, lowering the risk of casting defects and enhancing overall quality.

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Our Full Mold casting Process






An expandable polystyrene foam pattern is precisely cut or molded to match the desired shape of the final casting.
The foam pattern is coated with a refractory material to create a heat-resistant barrier, enhancing the casting's surface finish.
The coated pattern is placed in a flask, and dry sand is compacted around it, providing support during the casting process.
When molten metal is poured directly upon it, the foam pattern is vaporized, and the cavity is filled with liquid metal.
The metal cools and solidifies within the sand mold, maintaining the exact shape and details of the original foam pattern.
The sand mold is broken apart, and the completed casting is removed once the metal has cooled, ready for any necessary post-processing.
Full Mold casting Materials
Full Mold Casting enables precise production of complex and intricate designs. It offers tight tolerances and excellent control over dimensional accuracy.
These alloys provide excellent strength-to-weight ratios with good fatigue resistance. They are ideal for aerospace frames and automotive parts requiring lightweight durability.
Known for high tensile strength and impact resistance, ductile iron retains flexibility, making it perfect for heavy machinery parts subject to dynamic loads.
These grades offer outstanding corrosion resistance and are highly stable under extreme temperatures. They are suitable for chemical processing equipment and marine applications.
Copper-nickel alloys combine excellent resistance to seawater corrosion with good thermal conductivity. They are commonly used in marine fittings and heat exchangers.
High-carbon steel delivers superior hardness and wear resistance, making it suitable for industrial tools, dies, and high-strength components.
Inconel alloys are known for their exceptional oxidation and creep resistance at high temperatures. They are used in aerospace turbines and power generation systems.
Ensuring Consistent Material Properties Across Large Batches
In Full Mold Casting, the solidification process is closely controlled to ensure uniformity in material properties. Utilizing a consistent cooling rate and minimizing thermal distortion promotes an even distribution of strength, density, and mechanical characteristics. The vaporization of the polystyrene pattern eliminates the risk of variation due to traditional mold setup. Frigate’s precise control over the process results in castings that maintain uniform properties across large batches, ensuring reliability and consistency in high-demand applications.

Compliance for Full Mold Casting Services
We are committed to upholding the highest standards in Full Mold Casting services. We comply with stringent industry regulations to ensure precision, reliability, and safety in every casting. Our services meet the specific needs of high-performance sectors such as aerospace, automotive, and electronics. We guarantee that all castings meet or exceed the required specifications by adhering to strict quality control measures.
Quality management system standard for consistent excellence in production (Certification No. 12345).
Restriction of hazardous substances in electronic and electrical equipment.
Standard specification for aluminum alloy castings used in industrial applications.
Compliance with European Union regulations on the safe use of chemicals in manufacturing.
Environmental management system to reduce environmental impact (Certification No. 67890).
Aerospace quality management standard (Certification No. 11223) for stringent aerospace component requirements.
Compliance with Federal Aviation Administration standards for aerospace castings and materials.

Tolerance for Full Mold Casting Services
Tolerance in the overall dimensions of cast parts, influenced by material, complexity, and mold design.
The roughness average (Ra) indicates surface texture, important for friction reduction and aesthetic purposes.
Tolerance for casting wall thickness, impacting mechanical strength, heat distribution, and product longevity.
Tolerance in the linear dimensions critical for assembly and precise fitting with mating parts.
Angular deviations, ensuring parts align correctly during assembly and fit into complex structures.
Variations in casting weight due to material consistency, process control, and design specifications.
Tolerance for holes or inner features to ensure tight tolerances for shafts, bolts, or other mating components.
Deviation from a flat surface, ensuring stability and effective assembly when parts must lie flush against each other.
Deviation from perfect circularity, critical for functional parts such as shafts or gears where rotational accuracy is essential.
Tolerance for depth in molds, critical for ensuring the correct material distribution and component fit.
Deviation in the position of internal cores during casting, affecting the final shape and fit of internal cavities.
Variation in the thickness of different sections of the casting, influencing cooling rates and mechanical properties.
Deviation from parallelism between two surfaces, ensuring proper alignment in assemblies requiring flatness.
The tolerance of how centered one feature is relative to another, crucial for parts with rotating or moving components.
Deviation in the angle of tapered surfaces, critical for parts that require accurate fits or efficient material flow during casting.
Variations in material composition, ensuring alloy purity and homogeneity for consistent mechanical properties across parts.
The required strength for bonding areas, ensuring the integrity of cast parts under stress.
Efficiency of the mold filling, ensuring that the cavity is completely filled with minimal porosity or defects.
Maximum allowable porosity in the final cast, critical for maintaining structural integrity and functionality.
Variability in dimensions due to material contraction during solidification, affecting the final size and fit of parts.

Quality Testing Standards for Full Mold Casting Services
Provides detailed, non-destructive internal analysis of wall thickness and material integrity, especially in complex geometries.
Advanced scanning technology for rapid and accurate dimensional measurement of complex parts.
Verifies critical geometric features like angle, flatness, and perpendicularity, ensuring compliance with design specifications.
Ensures that the final casting weight is within the specified tolerance for material consistency.
Measures internal diameters with high precision for ensuring accurate fit for mating components.
Detects any deviation from a flat plane, which is crucial for parts that must mate with other flat surfaces.
Ensures that rotating parts (like shafts) maintain precise circular geometry with minimal deviations.
Measures depth of mold cavities, ensuring uniform fill and minimal deviations in thickness, especially for deep or complex parts.
Non-destructive imaging technologies to detect shifts in core placement during solidification.
Ensures uniformity of thickness throughout complex castings to avoid weak spots and ensure load-bearing capacity.
Measures parallelism between two surfaces to ensure that components align accurately in final assembly.
Measures the alignment of concentric features, ensuring the precise fit of cylindrical or rotational parts.
Measures the taper angle of cast components to ensure proper fitting and material flow during casting.
Measures the chemical composition of alloys to ensure consistent material properties and purity.
Tests the tensile and bonding strength of cast materials to ensure that they meet mechanical performance standards.
Detects incomplete filling, voids, or cold shuts, ensuring that the mold cavity is fully filled and free from defects.
Non-destructive tests to identify internal voids and porosity, which can impact the part’s strength and durability.
Measures the final casting dimensions to ensure that shrinkage due to cooling is within specified limits.
Measures the material's resistance to fatigue under cyclic loading, important for components in dynamic environments.
Assesses the material's ability to absorb energy during impact, indicating toughness and resistance to brittle fracture.
Tests the hardness of cast materials, ensuring the final part meets the required wear resistance and durability.
Detects surface cracks, fissures, or other irregularities that may compromise the structural integrity of the cast part.
Measures material expansion or contraction during temperature changes, critical for ensuring dimensional stability in high-temperature applications.
Assesses the casting's ability to be welded effectively, ensuring proper integration with other components.
A Solution for Precision in Automotive Components
The need for high-precision and complex automotive parts often leads to difficulties in traditional casting methods. Full Mold Casting offers a more efficient solution, ensuring accurate dimensions and superior surface finishes with minimal porosity. Using vaporized foam patterns eliminates the risk of dimensional errors and allows for faster production cycles. This technique is ideal for manufacturing automotive components, including brake rotors, engine blocks, and structural parts, providing the necessary strength, durability, and accuracy for critical applications.






Industries We Serve
What You Get


↓ 7-8%
OPS COST

↓ 2-3%
COGM

3X
Aggregation

↑ 25%
Machinery Utilisation

↓ 50%
Expedition

↑ 30%
Frigater Revenue
Reducing Lead Times for Faster Production
Full Mold Casting reduces lead times by streamlining mold preparation. Using expendable foam patterns eliminates the need for complex tooling, accelerating the mold creation. This method allows for faster cycle times, reducing overall production delays. Frigate’s efficient approach to Full Mold Casting ensures that parts can be produced quickly while maintaining high precision. This reduction in lead time is particularly beneficial for projects with tight deadlines, where quick turnaround without sacrificing quality is essential.

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Having Doubts? Our FAQ
Check all our Frequently Asked Question
The mold coating provides a smooth, uniform surface that ensures the precise replication of intricate features and minimizes defects such as porosity or surface imperfections.
By carefully controlling the mold temperature and pouring speed, Full Mold Casting minimizes material flow issues and solidification anomalies, ensuring uniform density and strength across the casting.
The vaporization of the polystyrene pattern during pouring leaves an exceptionally precise cavity, enabling tight dimensional tolerances and reducing the need for secondary machining processes.
Proper sand compaction around the pattern ensures structural integrity during the casting process, preventing mold shifting or collapse and maintaining the accuracy of the final casting shape.
The foam patterns' expendable nature allows for quick and cost-effective mold creation, making Full Mold Casting suitable for high-volume production while maintaining high consistency and minimal scrap.
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LOCATIONS
Global Sales Office
818, Preakness lane, Coppell, Texas, USA – 75019
Registered Office
23, 6th West Street, Balaji Nagar, Kattur, Pappakuruchi, Tiruchirappalli-620019, Tamil Nadu, India.
Operations Office
9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ