Impro is a worldwide leader in investment casting, a process of forming metal that typically uses a wax pattern surrounded by a ceramic shell to make a ceramic mold. When the shell dries, the wax is melted away, leaving only the mold. Then the casting component is formed by pouring molten metal into the ceramic mold.
Advantages of Investment Casting
There are numerous benefits of investment casting. The process can eliminate secondary processes after casting and reduce tooling costs over several production runs. With an extensive selection of alloys to choose from, the final parts display accurate and smooth surfaces, low tolerances, and allow for lower weight with thin walls. The design flexibility has a wide range so parts can be produced in almost any size or complexity. Other methods do not provide the same tolerance levels.
Impro’s Investment Casting Capabilities
Impro is capable of meeting material specifications according to ASTM, SAE, AISI, ACI, DIN, EN, ISO, and GB standards. We have more than 100 different ferrous and non-ferrous alloys with which we cast parts using a complex design criteria. Our dimensionally and geometrically complex investment castings are produced to net shape, minimizing the need for secondary machining. Our top of the line equipment and automation process controls allow for consistent and repeatable tolerances as close as ±0.1 mm. Our castings can also be produced in a wide size range. They be as small as 10 mm long x 10 mm wide x 10 mm high and weigh as little as 0.01 kg, or as much as 1000 mm in length and weigh as much as 100 kg.
At Impro, we pride ourselves in offering our customers the highest-quality service from start to finish. Our services include:
In-house tooling design and manufacturing capabilities.
Our global clients include companies in the automotive, aerospace, and medical industries. We employ numerous non-destructive and laboratory test methods on site in our quality lab to verify precision of internal structure and material composition. Our highly-skilled engineers, chemists, and technicians handle order loads from a few pieces to several million per year.
As the global leader in investment casting manufacturing, we take pride in offering only the best services on the market. Our passion for outstanding customer service leads our drive for excellency. To learn more about our services or discuss options for your next project, reach out to the team today.
Investment casting of complex precision parts requires high-quality equipment capable of achieving tight tolerances with repeatable accuracy. Machinery and manufacturing processes must also be able to process large volumes quickly and seamlessly without compromising product quality.
At Impro, we employ the latest in advanced technology and cutting-edge process equipment at various phases of the investment casting process. Tooling design, wax pattern injection, wax pattern assembly, shell-making, pouring, heat treatment, and testing are all performed using the best available machinery, operated by our qualified team of experts.
Impro’s fleet of wax injection equipment consists of more than 50 sets of MPI fully automatic and semi-automatic wax injection machines. MPI’s industry leading injectors allow us to achieve higher casting yields and reduced lead times for high volume production runs. Our automated conveyor chain is integrated with the automatic cleaning line and seamlessly connects to the wax pattern and shell making shop. Our emphasis on process automation helps to minimize the risk of handling damage.
Robotic Shell Making Lines
Expertly programmed robotics are highly reliable and eliminate coating and stability errors associated with manual operations. Our robotic equipment performs 360-degree automatic coating, stuccoing, and suspension line hanging with minimal human intervention. Lights-out automation allows our shell-making line to operate 24 hours a day, seven days a week.
Robotic Wax Pattern Assembly Line
Our fully automated robotic wax pattern assembly line replaces conventional manual methods of pattern assembly and is capable of running around the clock. The manually time-consuming pattern assembly process is performed by our system of robotic arms, resulting in significant improvements in our assembly process, faster lead times, and enhanced product quality and consistency.
Multi-purpose Heat Treatment Line
Our heat treatment line consists of equipment from industry leading furnace solutions provider, AICHELIN. Our automated, CNC-controlled heat treatment line can perform multiple operations such as conditioning, carbon restoration, carbonitriding, and tempering of carbon and low alloy steels. Our heat treatment line runs 24 hours a day with only manual loading and unloading required when necessary.
Laboratory Inspection and Testing
All casted products are thoroughly inspected in accordance with stringent internal quality management procedures to ensure compliance with customer and industry specifications and standards. Our inspection arsenal consists of three coordinate measuring machines (CMM) capable of verifying dimensions within fractions of a micron. We also employ strict PPAP and process flow verification procedures to guarantee the quality of all materials during the manufacturing process.
Final inspections processes are further augmented with our multi-station automatic X-ray testing systems. This ensures that all products that leave our facility are free from internal defects such as gaps, cracks, holes, or inclusions that may compromise the component’s structural integrity.
Investment Casting with Impro Industries
Impro’s investment casting techniques can meet even the most challenging customer demands and specifications. To discuss how our advanced equipment and processes can transform your investment casting project, please contact our team of experts or submit a request for information.