If you have been tuning in to the Protocast Inc. blog, you have likely come to the conclusion that our experienced team can complete just about any casting project that you might throw at us. In a sense, if you have a product, tool, or prototype that needs to be manufactured and fine-tuned, we can make it with a little bit of strategy, molten metal, specialty molds, and elbow grease.

One of the production methods that we use quite often here in our Denver foundry is the plaster mold casting method. 

As you already know, casting is the act of pouring molten metal into a specially designed mold of your prototype or tool. After the metal alloy cools off and hardens, it can be removed from the die (mold) and undergo various finishing treatments ranging from hardening to machining and finishing. 

The casting process is extremely intricate, and because of that, Protocast Inc. is proud to provide companies and individuals in the automotive, aerospace, defense, robotics, and oil and gas industries with high-quality alloy casts and CNC machined parts — including parts and tools made using the rubber plaster mold process.

But how exactly does the rubber plaster mold casting process work?

Rubber Plaster Mold Production

Rubber plaster mold casting, otherwise known in the industry as rubber plaster casting, is a technique of mold building that allows for the fabrication of a flexible rubber plaster mold that can be used multiple times to cast intricate metal parts. To make these flexible casting molds, a mixture of gypsum, water, and strengthening compounds are used to create a mold. In most cases, the plaster mold is made using a mixture of additives that contribute to the overall green strength, dry strength, and permeability and castability of the mold. 

During the plaster casting production process, a parting line in the mold must be determined — and in some cases there will be multiple parting lines so that more complex casts can be made. The placement of the parting lines allows for the easy removal of the cast so that the cast can be used again repeatedly. At Protocast Inc., we recommend that our rubber plaster molds be used from anywhere between 5 and 250 times to ensure that the quality of the mold remains constant. 

Why Use Plaster Mold Casting?

Plaster mold casting allows our foundry to fabricate complex parts — not to say that other casting methods that we utilize in our Denver foundry can’t be used to make complex parts too. What makes plaster mold casting so intricate and exact during the casting process is the low thermal conductivity and heat capacity of the mold. Because the cast has a lower heat capacity and thermal conductivity, the liquid alloy in the mold cools slower than it would in a traditional sand mold. When the alloy cools slower, the metal will fill in evenly across the cross-sections of the mold.

If you believe that this innovative method of alloy mold casting might be right for your next project, we urge you to contact us at our Denver foundry. Upon contacting us, a member of our team will discuss your project with you and provide you with the full scope of the services that we can include to bring you the highest-quality mold.  

Why Choose Protocast INC. as Your Go-To Foundry? 

At Protocast Inc., we have always adapted to provide our customers with the best casting and machining services in the Denver area.

In 1995, Protocast Inc. was founded, specializing in 3D printing technology, speed, quality, and customer care. Over the years, however, it was apparent that our customer base needed other alternative prototype and tooling production methods. In 2002, we began to offer more innovative services and production solutions. 

These production solution services included:

CNC Machining – While we quickly became one of the most established casting companies in Colorado, there was an inherent need for high-quality, complete metal parts and prototypes. Because of this, we decided to begin offering our customers alloy casting and CNC machining. 

Sand Casting – While the rubber plastic mold that we discussed in today’s blog is one of the best alloy casting methods for producing high-quality parts and prototypes that don’t need extensive machining, sand casting is a production method that we were eager to offer to our clients —Now it is almost half of our business!

Investment Casting – If you are noticing a trend, it is that there are many different types of casting — all of which have their own benefits. Investment casting, however, is a little bit different than the rest. Perfect for smaller, low-volume projects, investment casting does not require a mold to be manufactured. Investment casting lets us make smaller, more complex parts at a more affordable rate to you!

If we were to keep talking about all of the different casting and machining techniques that we have implemented since 2002, it would take all day. So instead of continuing, we will just say that we are proud to offer such high-quality manufacturing methods to our clients in the Denver area. 

Need Casting? Contact Us Now!

If you need high-quality casting and machining services, we urge you to get in touch with a member of our Denver foundry. If you have any questions about our process or about the abilities that we have here in our foundry, we urge you to contact us.

We look forward to working with you on your next project.