Investment Casting Rapid Prototyping

From one off highly complex components – to batches of several hundred

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Prototype Investment Casting, Waxes & Patterns

From one-off highly complex components – to batches of thousands

Regardless of size, complexity or quantity, we have a choice of processes to produce your custom investment castings in most metals including; Aluminium, Zinc, Titanium, Steels, and magnesium. We specialise in producing the investment casting “waxes” and then subcontract out to a selection of foundries that have been specifically chosen for their material choice, quality and willingness to do prototype runs alongside their production. So whether you require waxes for your own foundry purposes or metal castings, we have the right process for you.

Looking to Produce Multiple Parts?

We can produce anything from one to thousands

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Techniques On Offer

Investment Casting Waxes from Silicone Tools

This solution is perfect for multiple waxes, especially when quantities are unknown, as extras can be produced in hours. This cost effective route produces waxes with the best surface finish over all three techniques. The wax itself is standard foundry wax, thereby replicating the exact production environment.

Techniques On Offer

SLA Quickcast™ using Watershed™ 11120;

Direct patterns from 3D data within 2-3 days. Ideal for medium to large components. Compatible with standard foundry practises, Watershed™ material is the best choice resin for QuickCast™. It has low ash content (0.035%) and low antimony content (0.021%). It also has an HDT low enough to ensure pattern collapse during burn-out preventing shell burst. Improved accuracy, surface finish and larger one-piece patterns are advantages over Castform™.

SLS Castform™ PS;

Direct patterns from 3D data within 3-4 days. Ideal for medium-sized highly complex components. Excellent for complex models with features that would prove awkward or impossible to mould from standard tooling. MNL has developed a method to improve the surface finish to that of standard Castform™ products, giving aesthetically pleasing investment castings as well as functional ones. Although ideal for 1-offs, depending on size, 100s of waxes can be produced in only a few days. Advantages over Quickcast™ include even lower ash content (0.02%) and supports are not required, perfect for internal coring etc.

Investment Casting Case Studies

Waxes from Silicon Tools Produce Excellent Surface Finish Regardless of size, complexity or quantity, we have a choice of processes to produce your prototype investment castings in most metals including; Aluminium, Zinc, Titanium, Steels, and magnesium.
3D Printed SLS Castform "Waxes" are Excellent for Complicated Geometries “From one off highly complex components – to batches of several hundred”
View this project 3D Printed SLA QuickCast "Waxes" for Large Complex Accurate Patterns Whether you require a simple sand casting pattern, or a large intricate investment ‘wax’ complex piece of jewellery, Malcolm Nicholls Limited (MNL) has the technology to help you out.
View this project Complex Geometries can be Produced in Hours We specialise in producing the investment casting “waxes” and then subcontract out to a selection of foundries that have been specifically chosen for their material choice, quality and willingness to do prototype runs alongside their production. So whether you require waxes for your own foundry purposes or metal castings, we have the right process for you.
Investment Waxes Produced from Silicon Tools This solution is perfect for multiple waxes, especially when quantities are unknown, as extras can be produced in hours.
Extremely Complex Components are Perfect for the SLA Castform Process Direct patterns from 3D data within 2-3 days. Ideal for medium to large components. Compatible with standard foundry practises, Watershed™ material is the best choice resin for QuickCast™.
Internal Forms are Perfect via the SLS Castform Process MNL have developed a method to improve the surface finish to that from standard Castform™ products, giving aesthetically pleasing castings as well as functional ones.
Plaque made via Sand Casting from 3D Printed Master Pattern This solution is perfect for multiple waxes, especially when quantities are unknown, as extras can be produced in hours. This cost effective route produces waxes with the best surface finish over all three techniques. The wax itself is standard foundry wax, thereby replicating the exact production environment.
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Transparent 3D Printing FAQs

What is investment casting rapid prototyping?

Investment casting services are used to rapidly create metal prototype parts from CAD data using wax patterns. Silicone tooling and 3d printed patterns can also be used as an alternative to wax. Long lead times often associated with traditional tooling can be reduced and highly accurate cast components are produced.

What types of metals can be used for prototype investment castings?

Custom investment castings can be produced in a variety of materials including steel, aluminium, zinc, titanium and magnesium.

Can highly complex internal geometries be cast?

Yes you are able to. Processes such as SLA Castform™ are suitable for undercuts, internal forms and intricate geometries; conventional moulding methods struggle to achieve these results.

Is investment casting suitable for functional prototypes?

Yes, our investment casting services can be used to produce fully functional metal prototypes and surface finishes.