The Unicast Process lets you build tooling on a "do-it-yourself" basis. It involves a simple metal casting system that can easily be installed in any factory or workshop. All alloys can be cast, including steel, iron, bronze alloys, beryllium copper (BeCu) and beryllium nickel, kirksite (zinc or zamak), and aluminum.
The patented process covers preparation of an extremely accurate ceramic foundry mold into which the metal is cast. Patterns can be made from any material-wood, epoxy, plaster (gypsum), metal, rubber, etc. or even from an original model or part. Stereo-lithography patterns are frequently used, especially with regard to rapid prototyping.
Cast tools are ideal where cavity details geometry make conventional machining difficult or expensive. Textured detail such as wood or leather grain or heavily contoured sections, are good examples. Machine finishing is usually reduced to matching, fitting, and insertion of mold pins. Cooling systems can often be cast directly into the mold and require no machining.
Packaging, automotive, furniture, shoes, toys, buttons, tires, and foundry - these are just a few of the many industries offering major opportunities for cast tooling.
Prototype tools are another outstanding application. New or confidential designs can be tried or test marketed without the high cost or long delivery of conventional tooling. And cast prototype tools can frequently be used for production - cast alloys often have better strength and wear characteristics than their machined counterpart.
More and more companies worldwide are installing the Unicast Process to produce their own injection molds, blow molds, and similar tooling. Others are making permanent molds and die-casting cavities, glass molds, rubber molds, slush molds, foundry patterns and coreboxes, and even extrusion and forging dies. There is very little limit to the type of tooling that can be cast.
Installation costs are extremely modest and often consist of a simple melting furnace, curing oven and ceramic mixer. Special skills are not required and Unicast engineers can train your people as well as provide technical assistance on layout and manufacturing.
The Unicast Process is available on a simple licensing basis to suitably qualified firms. Costs are modest and full details will gladly be provided on request.