The Investment Casting Process

Investment casting is a precision manufacturing technique widely used across industries to create complex and high-quality metal parts. At NOVA, we leverage this sophisticated process to deliver exceptional components tailored to our customers' exact specifications. Here’s a detailed overview of the investment casting process:

Step 1: Engineering Review
Every successful project starts with a comprehensive Design For Manufacturing (DFM) review. Our engineering team collaborates closely with customers to evaluate part dimensions, wax injection mold design—including gate placement—and post-casting requirements such as material properties and tolerance standards. This ensures the final casting meets strict criteria for fit, form, and function.

Step 2: Mold Design & Fabrication
Using advanced precision engineering, we design and build wax injection molds in-house. These molds are engineered for durability and accuracy, capable of producing millions of wax patterns that represent the final cast parts.

Step 3: Wax Pattern Production
Wax is injected into the molds and the resulting patterns are assembled onto a wax “tree” — a pre-fabricated runner system. This cluster of wax parts is prepared for the next critical stage.

Step 4: Ceramic Shell Construction
The wax tree undergoes multiple cycles of dipping in ceramic slurry and coating with fine sand, building up a strong ceramic shell. This lamination process is repeated 6 to 8 times, with drying intervals to ensure a robust mold capable of withstanding molten metal.

Step 5: De-waxing
The ceramic shell, still containing the wax inside, is placed in an autoclave where high-pressure steam rapidly melts and removes the wax, leaving a hollow ceramic mold. This "lost wax" step is key to achieving intricate shapes and details.

Step 6: Metal Pouring
The ceramic mold is heated to approximately 1000°C to cure and prepare it for metal casting. Molten metal is then poured into the mold cavity, completely filling the intricate shape.

Step 7: Shell Removal & Casting Separation
Once cooled, the ceramic shell is broken away using water jets and vibration. Castings are carefully separated from the metal gating system by cutting or cryogenic methods.

Step 8: Finishing Operations
Final steps include removing gates, heat treatments such as annealing, machining, plating, or surface hardening. Each part undergoes thorough inspection before delivery to ensure top quality.

At NOVA, our investment casting process combines precision engineering, advanced materials, and rigorous quality control to deliver products that exceed customer expectations. We continuously innovate to meet the evolving demands of industries such as automotive, mining, and construction.