Scope of supply
- Investment castings by the ceramic shell process in carbon and low-alloy steels, stainless steels and related alloys for general industrial use. Other alloy families in the materials database are offered subject to confirmation for the part concerned.
- Engineering review: casting feasibility, design-for-manufacture proposals, material selection and clarification of cast grade and standard, tolerance and datum concept, inspection planning.
- Tooling: wax injection dies designed and built for the part; for prototypes and very small quantities, pattern routes without hard tooling can be evaluated.
- CNC machining of functional features, including turning, milling and multi-axis machining, so that parts are delivered ready to assemble.
- Heat treatment to the material specification.
- Surface finishing: blasting, pickling and passivation, polishing and coatings as specified.
- Inspection and testing: dimensional inspection, material verification, non-destructive testing and documentation as agreed; see quality.
- Packaging and logistics for international delivery.
How the work is organised
LOSTWAX and Modulus Metal act as the engineering and supply organisation responsible to the customer. Manufacturing steps are carried out in three ways, and for each order it is stated which applies to which step:
| Category | Meaning |
|---|---|
| Performed by Modulus Metal | Engineering review, project management, supplier quality, inspection planning and, depending on the order, inspection and machining operations |
| Performed by qualified manufacturing partners | Casting and other production processes carried out in partner facilities selected and qualified for the part |
| Coordinated through the supply chain | Special processes and tests placed with specialist providers, for example particular heat treatments, coatings, non-destructive tests or accredited laboratory tests |
Not all processes take place in one factory, and not every process listed in the technical library is available for every part. The production route, the facilities involved and their relevant certificates are disclosed to the customer during quotation and qualification as required.
The wider Modulus Metal range
Where investment casting is not the best route for a component, alternatives can be evaluated within the same organisation. The Modulus Metal range includes investment casting, sand casting, die casting, gravity casting, centrifugal casting, CNC turning and milling, 5-axis machining, plastic injection moulding, sheet metal manufacturing, laser cutting, bending, welding and manufacturing supply-chain management. Details are available at modulusmetal.com.
Combining casting with further operations
Combining the casting with machining, heat treatment, finishing and inspection under one responsibility has practical advantages: datum targets and machining allowances are coordinated, casting defects exposed by machining are handled without dispute between suppliers, and the customer receives one set of documents for the finished part.
Typical project sequence
- Enquiry with drawing, 3D model and requirements.
- Engineering review and clarification; quotation with stated production route.
- Order, tooling design and manufacture.
- Initial samples with agreed reports; correction and approval.
- Series production to the control plan.
- Delivery with the agreed inspection documents.
What to send with an enquiry is listed on the contact page.