Production process
Expertise and precision at every stage of the process
At our Sasso Marconi plant, with 7,000 m² indoors and 27,000 m² outdoors, we focus on the entire process, from wax injection and cluster assembly to finishing, control and delivery of the final product. This allows us to achieve high levels of quality, functionality, efficiency and competitiveness for every mechanical component produced.
Stages of the lost wax casting process
Wax injection
Presses inject liquid wax into a metal mould. Once it has solidified, the wax is removed from the mould to obtain the model of the component.
Stages of the lost wax casting process
Assembling the cluster
The wax models are attached to a sprue (a central wax stick) to form the cluster. This makes the models easier to handle in the subsequent stages of the process.
Stages of the lost wax casting process
Forming (immersion)
The cluster is dipped in a ceramic solution with the aid of a robotic system.
Stages of the lost wax casting process
Forming (shell building)
When the liquid layer is even and the excess fluid has dripped off, ceramic sands of increasing particle size are sprayed to cover the whole cluster, creating a ceramic coating. The overlapping of layers, with a few hours drying time in between creates a hard, strong shell.
Stages of the lost wax casting process
Dewaxing and heating
Once the shell is formed, the wax is put in a high-temperature autoclave to evacuate the wax, which is melted out from under the ceramic layers. The clusters, now emptied of the wax, are heated to reach the ideal casting temperature.
Stages of the lost wax casting process
Pouring
The pouring is performed by electromagnetic induction melting furnaces using the rollover technique.
Stages of the lost wax casting process
Knock-out and cut-off
When the metal has cooled, the ceramic shell is fractured by vibration. The components are then separated from the gates and the parts are deburred.
Stages of the lost wax casting process
Finishing, mechanical machining and treatments
The components are carefully finished and heat-treated. If required, the castings can undergo machining and final treatments.
Stages of the lost wax casting process
Tests and certifications
After completion of the production stages, calibration, straightening and non-destructive testing are carried out. The certifications are then provided in accordance with the customer's specifications.
