There are 3 key elements that are required to successfully produce ceramic cores consistently: outstanding materials, rigid process control and optimised reliable production equipment. One of the biggest risks faced by investment casters and ceramic core producers is a loss of process knowledge that in most cases has been built up by indiviausls over several years, replacing this knoledge is very difficult if not impossible, therfore the lead times for training new employees can be extremtly protracted.
We supply a complete range of process instructions for all ceramic core manufacturing operations. These process instructions can be deployed within your existing process or in conjunction with any of our material or process solutions. Aquiring our process instructions not only ensures your process is robust and controlled but it also removes a significant element of risk around a loss of knowledge and skills in the future. Individual process instructions can be aquired as well as a complete set of instructions for the entire process. All process instructions are written in a step by step format with colour images for ease of understanding.
Our material mixing instructions cover every element of ceramic core material blending and mixing. They include key elements including mixing times, temperatures and a step by step guide for adding ingrediants.
Our injection moulding process instructions include key elements including temperatures, pressures and and several other key process steps and machine settings. We supply 3 different sets of instructions based on common product sizes and complexitys.
We have a number of kiln profiles avaiable that based on product size and complexity. Each of our kiln programmes include full heat up and cool down stages as well as instructions on optimised part orientation. Our kiln profiles are optimised for product performance, productivty and fuel efficency.
Once your ceramic cores have been fired they now need to be safely removed from the saggar, upwards of 15% of parts are often lost through bad practices at this process, our process instructions provide clear guidance for the safe, reliable and consistent unpacking of ceramic core post firing.
Penetrant inspection often refered to as 'white inspection' is a key process then ensures that non-conforming products are removed from the process as early as possible. Our process instructions provide step by step guidance on how to prepare the raw materials and succesfully complete this process.
CNC maching of ceramic cores provides signifcant productivity benefits to ceramic core producers. Our process instructions cover all elements of the CNC maching process, we also provide support on CNC programming and fixture design.
Hand finishing of ceramic cores is a vital and time consuming process. The skill and knowledge to succesfully finish ceramic cores is often built up over several years. We have developed a step by step guide for hand finishing that covers of a variety of ceramic core designs. Using our process instructions reduces training and development time by upwards of 75%.
Measuring ceramic cores using a CMM machine is relatiively simple, however there are a number of elements and process steps that can drastically affect the results obtained, our process instructions ensure each core is measured accurately and repeatably, we also provide CMM programming support and data capture support.
The ceramic core impregnation process is critical to product performance. Its vital to ensure this process is performed correctly as operated incorrectly can lead to drastic differences in part properties. Our systems are designed to not only optimise product performance but also to ensure operator comfort and safety.
Our ceramic core preperation instructions provide guidance on how to infill and surface prep ceramic cores prior to transport or wax injection. The process instructions include key parameters including material preperation, temperatures, suggested tools, application methods and cleaning processes.
Repairing surface defects on ceramic cores is not an process and can take several months of training in order for an operator to work independently. Using our process instructions details all of the required steps to ensure your operators are capable of repairing the most complex of cores in a matter of days.
This is the final time you will see your product before your customer does, whether that's an internal customer in the wax room or your external customer, reduce your risk and accelerate your results through the use of our training manuals.