Investment casting (lost-wax precision casting) is an engineered net-shape metal forming process manufactured using expendable wax patterns and ceramic refractory shells to produce complex aerospace, turbine, valve, pump, and industrial components with as-cast surface finishes down to 125 Ra (3.2 µm) and dimensional tolerances to ISO 8062-3 DCTG 4. ForceBeyond provides custom investment casting services for complex, near-net-shape metal components. Also known as the lost-wax process, investment casting uses a sacrificial pattern and ceramic shell to reproduce detailed geometry, thin sections, smooth surfaces, and features that may be difficult or uneconomical to machine from solid stock.
Programs may include stainless steel, carbon and low-alloy steel, nickel-based superalloys, and titanium investment casting. ForceBeyond coordinates casting, heat treatment, precision machining, HIP, surface finishing, inspection, assembly, and logistics through an integrated manufacturing network.
Investment casting is often selected when part complexity, alloy cost, surface finish, dimensional control, and reduced machining are more important than the lowest possible tooling cost.
The table below provides typical process guidelines. Final capability depends on alloy, geometry, part size, foundry process, tooling, production volume, and drawing requirements.
| Selection Factor | Investment Casting | Sand Casting |
|---|---|---|
| Surface Finish | Typically smoother; approximately 63–125 RMS may be achievable on suitable geometries. | Typically rougher; often approximately 250–500 RMS depending on molding process and alloy. |
| Dimensional Control | Typical linear tolerance may approach ±0.005 in/in, subject to geometry and foundry capability. | Broader tolerances are common, especially on larger parts and complex mold joints. |
| Wall Thickness | Small features may approach about 0.040 in (1.0 mm), subject to alloy and flow length. | Generally requires thicker sections, especially on large or long-flow geometries. |
| Part Size and Tooling | Best suited to small and medium complex components where precision offsets tooling cost. | Often preferred for larger parts, simpler geometry, and lower tooling investment. |
The investment casting process supports a broad range of ferrous and non-ferrous alloys. Material selection should consider mechanical properties, corrosion resistance, temperature, weldability, machinability, heat treatment, and applicable specifications.
| Material Category & Spec | Representative Alloys | Tensile Strength (UTS) | Yield Strength (0.2%) | Applicable Standard / Verification |
|---|---|---|---|---|
| Stainless Steel (ASTM A743) | 316L, 17-4 PH, CF8M | 75 – 150 ksi (517 – 1034 MPa) | 30 – 115 ksi (207 – 793 MPa) | ASTM E8 tensile, AMS 5355, ASTM E1417 (FPI) |
| Nickel Superalloys (AMS 5383) | Inconel 718, Inconel 625 | 100 – 145 ksi (689 – 1000 MPa) | 50 – 125 ksi (345 – 862 MPa) | ASTM E21 elevated temp, AMS 5401, ASTM E1742 |
| Titanium Alloys (ASTM B367) | Ti-6Al-4V Grade C-5 | 130 – 145 ksi (896 – 1000 MPa) | 120 – 135 ksi (827 – 931 MPa) | AMS 4991, ASTM E8, AS9100D, ISO 9001:2015 |
| Carbon & Low-Alloy (ASTM A216) | WCB, 8620, 4140 | 70 – 105 ksi (483 – 724 MPa) | 36 – 85 ksi (248 – 586 MPa) | ASTM A148, ASTM E1444 (MPI) magnetic particle |
Early manufacturability review can reduce tooling changes, distortion, shrinkage risk, and unnecessary machining.
Prototype investment casting may use printed wax or SLA patterns to support design validation, low-volume production, and alloy testing before hard tooling is released. Production programs typically use dedicated wax-injection tooling for repeatability and cycle efficiency.
The best approach depends on annual volume, part size, pattern cost, inspection requirements, delivery timing, and expected design changes.
Near-net investment casting can reduce material removal, but many functional parts still require coordinated secondary operations.
Investment casting generally provides finer surface finishes, tighter dimensional control, thinner walls, and greater geometric detail than sand casting. Sand casting is often more economical for larger parts, simpler shapes, and lower tooling budgets. Final process selection depends on alloy, geometry, part size, production volume, tolerance, surface finish, and cost targets.
Wall thickness depends on alloy fluidity, part size, flow length, geometry, local section transitions, and foundry process capability. Small features may approach approximately 0.040 in (1.0 mm), while more conservative designs often use 0.060 to 0.125 in or greater. Minimum wall thickness should be confirmed during manufacturability review.
Yes. Prototype programs may use 3D-printed patterns, printed wax, or SLA patterns to produce ceramic shells without committing immediately to hard production tooling. This approach can support design validation, alloy testing, fit checks, and low-volume development before production tooling is released.
Provide a 2D drawing and, when available, a 3D CAD model, along with material grade, annual and batch quantity, critical tolerances, wall-thickness requirements, surface finish, heat treatment, HIP, machining, inspection, certification, and delivery requirements. Clearly identify critical-to-quality features and any customer or industry specifications.
Send your drawing, CAD model, material grade, quantity, tolerance, wall-thickness, machining, heat-treatment, inspection, and delivery requirements for an engineering review.
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