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1751 432 355  \n[www.sylatech.com](www.sylatech.com)  \nFor the casting process  \nCONTENTS  \n1 THE SYLATECH CASTING PROCESS 1  \n2 DESIGN CONSIDERATIONS  \n2.1 Casting tolerances 3  \n2.2 Wall sections 4  \n2.3 Cast Holes 6  \n2.4 Draft angles 7  \n2.4 Special features-soluble cores, wax assembly, cast gears/teeth 7  \n2.6 Surface finishes 8  \n2.7 Integrated labelling-logos, lettering, numbers etc 9  \n2.8 Applied surface treatments 10  \n2.9 Heat treatment 10  \n3 GALLERY 11  \n4 METAL SPECIFICATIONS  \n4.1 Aluminium alloys, mechanical properties and comparisons 13  \n4.2 Copper alloys, mechanical properties and comparisons 15  \n\n| 5 TOOLING |  |\n| --- | --- |\n| 5.1 Gate witness | 17 |\n| 5.2 Types of tools | 18 |\n| 6 MACHINING | 20 |\n| 7 SUPPLY OF DESIGN INFORMATION | 21 |\n| 8 INSPECTION/QUALITY ASSURANCE |  |\n| 8.1 Control techniques | 22 |\n| 8.2 Inspection criteria | 22 |\n\nAPPENDIX  \nDatum systems inside back cover  \n1 DESIGN GUIDE  \nPRECISION INVESTMENT CASTING PROCESS WHY USE THE SYLATECH CASTING PROCESS  \nThis guide will enable the designer to take advantage of the technical and commercial benefits offered by the Sylatech casting process. Design ideas and considerations are included to help stimulate the design process.  \nSylatech continues to develop its process to meet the ever more exacting market challenges. For any aspect not covered by this guide, please contact our Sales Engineers who will share their experience, offer advice and assist in the design of your components.  \nFor over fifty years Sylatech has refined its techniques for excellence in the production of copper and aluminium alloy investment castings. Sylatech combines its impressive investment casting technology with best practice CNC machining, so allowing many of the constraints placed on engineering design to be overcome. This is all carried out within the BSI AS9100 Quality System.  \nu Reduce overall costs by Designing for Manufacture: simplify an assembly by combining a number of parts, eliminate joining processes and reducing the part count whilst improving the integrity of the finished product.  \nu Reduce time to market through the use of Rapid Prototyping technology and obtain casting, machining, assembly and packaging from one source. Finished metal parts can be delivered from concept in under four weeks.  \nu Design flexibility, with quick modifications to tooling that costs 90% less than for a pressure die casting, whilst maintaining economic batch quantities of up to 150,000 parts per annum.  \nu High quality finish, detail and specification.  \nWHAT THE SYLATECH CASTING PROCESS CAN DELIVER  \nu Thin walls as fine as 0 . 2 mm (0 .008”), typically 1-3 mm (0 .04” – 0 . 12”) .  \nu Light weight components, weighing as little as 1g can be produced using techniques to minimise material usage whilst retaining component integrity.  \nu Ideally a maximum size of 190 mm x 160 mm x 160 mm (8” x 6” x 6”). A length of 250 mm (10”) is possible providing  \nno other dimension exceeds 100mm (4”) . Larger sizes can be considered on a case by case basis.  \nu Complex detail on internal and external features.  \nu Super-fine surfaces with 0 .8 micrometres (32 micro inches) being the “as cast” finish. Zero draft angle.  \n2 DESIGN CONSIDERATIONS  \n2.1 CASTING TOLERANCES 2.2 WALL SECTIONS  \nTolerances depend on the geometry of each part, but the following tolerances are suggested as a guide to designers.  \nLengths including hole diameters, held to:  \n\n| mm |  | inch |  |\n| --- | --- | --- | --- |\n| Section | Tolerance | Section | Tolerance |\n| 0 – 15 | ±0.08 | 0.0 – 0.6 | ±0.003 |\n| 15 – 25 | ±0.13 | 0.6 – 1.0 | ±0.003 |\n| 25 – 50 | ±0.25 | 1.0 – 2.0 | ±0.010 |\n| 50 – 75 | ±0.37 | 2.0 – 3.0 | ±0.015 |\n| 75 – 100 | ±0.50 | 3.0 – 4.0 | ±0.020 |\n| 100 – 125 | ±0.60 | 4.0 – 5.0 | ±0.025 |\n| 125 – 250 | ±1.00 | 5.0 – 10.0 | ±0.040 |\n\nFLATNESS  \nGenerally held to ±0 . 13mm (","cbCaihWBLJsBN3un","https://ap.wps.com/l/cbCaihWBLJsBN3un","pdf",2055368,15,"English","# THE SYLATECH CASTING PROCESS\n# DESIGN CONSIDERATIONS\n## Casting tolerances\n## Wall sections\n## Cast Holes\n## Draft angles and special features\n## Surface finishes\n## Integrated labelling\n## Applied surface treatments\n## Heat treatment\n# GALLERY\n# METAL SPECIFICATIONS\n## Aluminium alloys\n## Copper alloys\n# TOOLING\n## Gate witness\n## Types of tools\n# MACHINING\n# SUPPLY OF DESIGN INFORMATION\n# INSPECTION/QUALITY ASSURANCE\n## Control techniques\n## Inspection criteria\n# APPENDIX\n## Datum systems","[{\"question\":\"What benefits does the guide claim for designing with the Sylatech casting process?\",\"answer\":\"It describes advantages such as reduced overall costs via design for manufacture, shorter time to market using rapid prototyping, improved design flexibility through low-cost tooling modifications, and high-quality finish and specification.\"},{\"question\":\"What guidance is provided for casting tolerances and geometric control?\",\"answer\":\"The guide provides suggested tolerances based on length ranges, plus typical flatness, straightness, and squareness/angularity limits, and notes how using a central feature as a datum can improve cast detail.\"},{\"question\":\"Which surface finishes and surface treatments can be applied?\",\"answer\":\"It lists guidance on super-fine “as cast” finishes, integrated labelling, and treatments including chromate conversion (ALOCROM), anodising limits for aluminium alloys, plating, and HIPping (hot isostatic pressing) to improve mechanical properties.\"}]","Design Guide - For the casting process | PDF",38]