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. 

Our Clients

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

Pattern Creation

An expandable polystyrene foam pattern is precisely cut or molded to match the desired shape of the final casting. 

Coating Application

The foam pattern is coated with a refractory material to create a heat-resistant barrier, enhancing the casting's surface finish. 

Mold Preparation

The coated pattern is placed in a flask, and dry sand is compacted around it, providing support during the casting process. 

Metal Pouring

When molten metal is poured directly upon it, the foam pattern is vaporized, and the cavity is filled with liquid metal. 

Cooling and Solidification

The metal cools and solidifies within the sand mold, maintaining the exact shape and details of the original foam pattern. 

Casting Removal

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. 

High-Strength Aluminum Alloys (e.g., A356, 6061)

These alloys provide excellent strength-to-weight ratios with good fatigue resistance. They are ideal for aerospace frames and automotive parts requiring lightweight durability. 

Ductile Iron (Grade 60-40-18, 65-45-12)

Known for high tensile strength and impact resistance, ductile iron retains flexibility, making it perfect for heavy machinery parts subject to dynamic loads. 

Austenitic Stainless Steel (Grades 304, 316)

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 (e.g., CuNi90/10, CuNi70/30)

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 (e.g., AISI 1045)

High-carbon steel delivers superior hardness and wear resistance, making it suitable for industrial tools, dies, and high-strength components. 

Inconel® Alloys (Inconel 625, 718)

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. 

ISO 9001:2015 Certification (QMS)

Quality management system standard for consistent excellence in production (Certification No. 12345). 

RoHS Compliance (Directive 2011/65/EU)

Restriction of hazardous substances in electronic and electrical equipment. 

ASTM A356-22

Standard specification for aluminum alloy castings used in industrial applications. 

REACH Regulation (EC No. 1907/2006)

Compliance with European Union regulations on the safe use of chemicals in manufacturing. 

ISO 14001:2015 Certification (EMS)

Environmental management system to reduce environmental impact (Certification No. 67890). 

AS9100D Certification

Aerospace quality management standard (Certification No. 11223) for stringent aerospace component requirements. 

FAA Regulations (14 CFR Part 21)

Compliance with Federal Aviation Administration standards for aerospace castings and materials. 

Tolerance for Full Mold Casting Services

Dimensional Accuracy
±0.1 mm to ±0.5 mm

Tolerance in the overall dimensions of cast parts, influenced by material, complexity, and mold design. 

Surface Finish
Ra 3.2 µm to Ra 6.3 µm

The roughness average (Ra) indicates surface texture, important for friction reduction and aesthetic purposes. 

Wall Thickness
±0.5 mm to ±2.0 mm

Tolerance for casting wall thickness, impacting mechanical strength, heat distribution, and product longevity. 

Linear Dimensions
±0.5% to ±1.0% of nominal dimension

Tolerance in the linear dimensions critical for assembly and precise fitting with mating parts. 

Geometric Tolerances
±0.5° to ±2°

Angular deviations, ensuring parts align correctly during assembly and fit into complex structures. 

Casting Weight
±2% to ±5%

Variations in casting weight due to material consistency, process control, and design specifications. 

Hole Diameter
±0.1 mm to ±0.3 mm

Tolerance for holes or inner features to ensure tight tolerances for shafts, bolts, or other mating components. 

Flatness
±0.2 mm to ±1.0 mm

Deviation from a flat surface, ensuring stability and effective assembly when parts must lie flush against each other. 

Roundness
±0.1 mm to ±0.5 mm

Deviation from perfect circularity, critical for functional parts such as shafts or gears where rotational accuracy is essential. 

Casting Depth
±1% to ±3%

Tolerance for depth in molds, critical for ensuring the correct material distribution and component fit. 

Core Shifting
±0.1 mm to ±0.3 mm

Deviation in the position of internal cores during casting, affecting the final shape and fit of internal cavities. 

Sectional Thickness
±0.5 mm to ±1.5 mm

Variation in the thickness of different sections of the casting, influencing cooling rates and mechanical properties. 

Parallelism
±0.1 mm to ±0.3 mm

Deviation from parallelism between two surfaces, ensuring proper alignment in assemblies requiring flatness. 

Concentricity
±0.05 mm to ±0.2 mm

The tolerance of how centered one feature is relative to another, crucial for parts with rotating or moving components. 

Taper Angle
±0.1° to ±1.0°

Deviation in the angle of tapered surfaces, critical for parts that require accurate fits or efficient material flow during casting. 

Material Consistency
±1% to ±3%

Variations in material composition, ensuring alloy purity and homogeneity for consistent mechanical properties across parts. 

Bond Strength
≥80% of material yield strength

The required strength for bonding areas, ensuring the integrity of cast parts under stress. 

Cavity Filling
98% to 100%

Efficiency of the mold filling, ensuring that the cavity is completely filled with minimal porosity or defects. 

Porosity
≤1% by volume

Maximum allowable porosity in the final cast, critical for maintaining structural integrity and functionality. 

Shrinkage
±0.1% to ±0.5%

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

Wall Thickness
X-Ray Computed Tomography (CT)

Provides detailed, non-destructive internal analysis of wall thickness and material integrity, especially in complex geometries. 

Linear Dimensions
Laser Scanning or 3D Scanning

Advanced scanning technology for rapid and accurate dimensional measurement of complex parts. 

Geometric Tolerances
Optical Comparator & Laser Measurement

Verifies critical geometric features like angle, flatness, and perpendicularity, ensuring compliance with design specifications. 

Casting Weight
Precision Balance Weighing

Ensures that the final casting weight is within the specified tolerance for material consistency. 

Hole Diameter
Bore Gauge or Digital Micrometer

Measures internal diameters with high precision for ensuring accurate fit for mating components. 

Flatness
Flatness Measurement (Dial Gauge, Laser)

Detects any deviation from a flat plane, which is crucial for parts that must mate with other flat surfaces. 

Roundness
Form Talysurf or Roundness Tester

Ensures that rotating parts (like shafts) maintain precise circular geometry with minimal deviations. 

Casting Depth
Depth Gauge, Laser Profiling, or Ultrasonic Testing

Measures depth of mold cavities, ensuring uniform fill and minimal deviations in thickness, especially for deep or complex parts. 

Core Shifting
X-Ray or CT Scanning

Non-destructive imaging technologies to detect shifts in core placement during solidification. 

Sectional Thickness
Ultrasonic Thickness Measurement

Ensures uniformity of thickness throughout complex castings to avoid weak spots and ensure load-bearing capacity. 

Parallelism
Laser Measurement or Precision Dial Indicator

Measures parallelism between two surfaces to ensure that components align accurately in final assembly. 

Concentricity
Concentricity Gauge or Coordinate Measurement

Measures the alignment of concentric features, ensuring the precise fit of cylindrical or rotational parts. 

Taper Angle
Digital Angle Finder or Protractor

Measures the taper angle of cast components to ensure proper fitting and material flow during casting. 

Material Consistency
Optical Emission Spectroscopy (OES)

Measures the chemical composition of alloys to ensure consistent material properties and purity. 

Bond Strength
Tensile Test & Fracture Toughness Testing

Tests the tensile and bonding strength of cast materials to ensure that they meet mechanical performance standards. 

Cavity Filling
X-Ray Inspection or Ultrasonic Testing

Detects incomplete filling, voids, or cold shuts, ensuring that the mold cavity is fully filled and free from defects. 

Porosity
X-Ray, Ultrasound, or CT Scanning

Non-destructive tests to identify internal voids and porosity, which can impact the part’s strength and durability. 

Shrinkage
Post-Casting Dimensional Measurement

Measures the final casting dimensions to ensure that shrinkage due to cooling is within specified limits. 

Fatigue Resistance
Rotating Bend or High-Cycle Fatigue Test

Measures the material's resistance to fatigue under cyclic loading, important for components in dynamic environments. 

Impact Strength
Charpy or Izod Impact Test

Assesses the material's ability to absorb energy during impact, indicating toughness and resistance to brittle fracture. 

Hardness
Rockwell or Brinell Hardness Testing

Tests the hardness of cast materials, ensuring the final part meets the required wear resistance and durability. 

Casting Integrity
Dye Penetrant Testing (PT)

Detects surface cracks, fissures, or other irregularities that may compromise the structural integrity of the cast part. 

Thermal Expansion
Dilatometers or Thermomechanical Analysis (TMA)

Measures material expansion or contraction during temperature changes, critical for ensuring dimensional stability in high-temperature applications. 

Weldability
Weldability Testing (Arc or MIG)

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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What Our Customers Say about Frigate

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Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does mold coating affect casting quality in Full Mold Casting?

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. 

How does Full Mold Casting handle variations in material flow and solidification rates?

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. 

How does Full Mold Casting accommodate high-tolerance casting requirements?

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. 

What role does sand compaction play in Full Mold Casting?

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. 

How does Full Mold Casting manage the challenges of large-scale production runs?

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

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