3D Plaster Casting

With over 20 years of experience, we combine 3D printing with plaster casting to create top-quality prototypes in aluminum, magnesium, and zinc.

We produce initial castings in just 5-10 working days and also take care of complex CNC machining, measurement reports, cleaning and much more. In other words we supply finished prototype parts.

100% In-house production
To guarantee prompt deliveries, we maintain 100% in-house production capabilities. Check out the video below and learn more about our streamlined process.

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Prototype i aluminium

Our plaster casting process - Step by step

Design of gating
The first step is 3D design of the gating system and adding machining allowance for the subsequent CNC machining process.

3D printing of PMMA models
The number of finished prototypes to be used will be printed as PMMA models first. The models are printed on our large in-house Voxeljet VX800 printer.

Plaster mould production
The printed PMMA models are embedded in plaster. The PMMA models are then burnt off at approximately 700 degrees. This forms a cavity in the plaster mould corresponding to the finished prototype in metal.

Casting
Molten aluminium or magnesium is poured into the plaster mould. When set, the plaster mould is smashed and plaster residue and gating system is removed from the cast prototype.

Finishing
When the parts are cast, we can carry out complex CNC machining at our state-of-the-art machining department.

Quality control
Before shipping the prototypes, we can measure and check them to ensure that they fully meet the customer’s requirements.

Plaster casting - technical specifications


STANDARD ALLOYS
• Aluminium AlSi7Mg – AB-42000
• Aluminium AlSi10Mg – AB-43000
• Magnesium AZ91
• Magnesium AM50
• Magnesium AM60
• Zinc Zamak 5

Other alloys on request.

TOLERANCES
Casting tolerances according to VDG P690, Accuracy grade D1.

SUITABLE NUMBER
1-50 pcs.

MAX. DIMENSIONS
700mm x 400mm x 400mm (larger items may be possible but will require further studies).

FINISH
Ra 6 to Ra 9