Machine Casting
Polymer Casting take on metals
CASTING epoxy/quartz composites can be precisely cast to size without secondary machining
A steel mold for casting digital scanner bases incorporates 160 vinyl tubing vacuum lines. The lines attach to the sides of steel mold and stay with the casting whe it is demolded. The 18-in-diameter semicircular drum has an ascast accuracy of 0.001-in.TIR.
Polymer/aggregate makes up all structural components of this milling machine except for the table
The impossible part. A 270 ° cylindrical scanner with 16 vaccum grooves, 2 meters long, cast to 0.001-in.TIR
Optical scanner base, cost 50% less than aluminum casting, took 2 days to produce versus 3 months for an aluminum casting and the machine operated 40% faster with better resolution. It was cast to .001" flatness overall and had multiple foam cores.
70,000 lb machining center, cast using a wood mold. Ways were grouted to tolerance.
Stainless Steel Replacement
Polymer Composite Chemical Pump
Machine specifications
Pump base used to mount pump and motor for chemical pumping
- Mounting surface flat to .0030"
- Stainless steel threads cast in place
- Plastic fitting for catch basin cast in place
Benefits
- Excellent chemical resistance
- Vibration dampening for longer pump life
- Sound deadening for quieter operation
- Low cost than stainless steel
- No machining required
- Catch basin cast in place
- Will not rust or corrode
- Heavy duty Construction
- Tooling cost depends on size
Cast Aluminum Replacement
Polymer Composite Laser Scanner
Machine specifications
High defination film imaging base with 2,000 rpm rotating drum.
- Castinite Polymer base 70"L X 39"W X 8"H
- Linear ways mounted directly to base
- Linear motor mounted directly to base
- Bearing blocks grouted onto base to .001 alignment
- EMI Shielding cast in
- Foam coring for reduced weight
- 150 corrosion resistant inserts cast in
- PVC ducting cast in
Benefits
- Significant cost savings vs aluminum casting
- Lower thermal expansion rate
- Shorter production time
- Superior surface finish
- Vibration dampening for improved image quality
- Quieter operation
- Will not rust or corrode
- Steel production mold cost $15,000
Precision Polymer Composite 4.5 million dollar Lithography system
This base is the heart of one of the world's most accurate hi-tech precision optical instruments in production today.
- Part cost $23,000-Mold cost $125,000
- 215 threaded inserts cast to + .005 TIR
- Hole diameters cast to + .0005/- .0000
- Datums cast flat & coplanar within .0005
- Selected over aluminum for improved vibration dampening, lower linear expansion & lower cost
- Greatly reduced lead time from 24 weeks to 8 weeks
Polymer Composite Vertical Turning Center
Machine specifications
- Travel X axis 38", Z axis 10"
- Travel rate X=1000 IPM, Z=500IPM
- Spindle speed to 6,000 rpm
- Turning diameter 10"
- Castinite polymer base 72"X48"X24" ; 3500lbs
- Steel way mounting surfaces cast in place
- Wire ducting cast in place
- Motor and ball screw mounting plate cast in place
Benefits
- Way surfaces cast into base using a low friction Polymer material
- Oil passages and oil lines cast in place
- Excellent vibration dampening
- Excellent chemical resistance
- Improved surface finish
- Vibration dampening improves wheel life and part finish
- Sound deadening provides quiet operation
Cast Iron Replacement
Polymer Composite Balancing Machine
Machine Specifications
- Casting Polymer casting 48" X 20" X 20"
- Balancing machine base cast with steel T-slotsS
- Foam core center with internal ribbing
- Smooth as cast surface finish
Benefits
- Damping improves balancing accuracy
- Foam core reduces weight and cost
- Steel T-slots cast into the top
- Steel bar cast in for gear rack
- Lower Cost
- Much better surface finish, ready for painting
- Low cost steel mold, $7,500
Weldment Replacement
Polymer Composite Milling Machine Stand
Machine Specifications
- Castinite Base 48" X 28" X 24" with open bottom for coolant reservoir
- Bed mill base replacing a steel weldment
- Casting includes coolant troughs and precise mounting pads
- PVC fittings cast through for the coolant drain
- Cover fasteners cast in place
Benefits
- Vibration dampening improves machined finish and increases tool life
- Sound deadening for quieter operation
- Chemical resistant, even to aggressive coolants
- Will not rust or corrode
- No secondary machining required
- Mounting pads cast to .001 coplanar
- Lower cost than weldment
- Improved stability
- Low cost mold, $5,500
Cast Iron Replacement
Polymer Composite Precision Laser Scanner
Machine specifications
Laser scanner base for film imprinting for high definition color
- Castinite base replacing cast iron;40L X 36D X 24W 18' diameter recess
- Radial surface cast to .002 TTR
- All surfaces cast flat and coplanar within .002
- 110 taped holes cast in place
- 48 vaccum grooves cast in
- 48 1.0mm diameter vacuum holes cast in place
Benefits
- 70% Lower cost
- Cast to tolerance reducing production time thus reducing inventory
- Will not rust or corrode
- Vibration dampening provides better imaging
- Higher production rate than cast iron therefore less W.I.P
- Approximate tooling cost $30,000
Polymer Composit CNC Knee Mi 11
Machine specifications
Job Shop ™ 3 axis CNC Knee mill
- Prototype knee mill produced using low cost tooling
- Castinite casting includes base, overarm, saddle, knee, and jack stand
- Base and overarm produced using steel molds; ways surfaces cast to tolerance
- Knee ways were steel angle segments
Benefits
- Vibration dampening provides longer tool life and better machined finish
- Excellent sound deadening for quieter operation
- No Secondary machining required
- Three month lead time to produce first parts
- Low cost tooling and parts
- Excellent surface finish
Polymer Composite Grinder Cross Ways
Machine specifications
- Surface grinder cross way
- Polymer casting, 82 inches long with a flat and "V" way
Benefits
- Way surfaces cast into base using a low friction Polymer material
- Oil passages and oil lines cast in place
- Excellent vibration dampening
- Excellent chemical resistance
- Improved surface finish
- Vibration dampening improves wheel life and part finish
- Sound deadening provides quiet operation
180 deg. Internal drum for CTP plate setter
High quality steel mold for the above casting. The drum incorporates 161 vaccum holes connected to the manifold via plastic tubing (the only process that can merge metal & plastic into the same casting)
180 deg. Polymer internal drum for a film Image setter
270 deg. Internal drum for film setter
Casting for a large CMM
Casting base for a laser inspection machine
180 deg. Small drum for film image setter
Casting in natural color. The aluminum sleeve is cast-in flat with the surface during the process.
Casting base for a screen printing machine. Semiconductor Industry.
One piece casting for a small CMM cast in grey color with a steel plate incorporated into the casting.
Casting for a computer chip bonding machine. Semiconductor Industry.
Casting for a medium size CMM.
