Rod. Engº Ermenio de O. Penteado, Km 47,6 - Indaiatuba/ SP Brazil

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Os moldes de injeção são produzidas através de processos de usinagem de alta precisão (via CAM – Computer-Aided Manufacturing). Seu composto é perfeitamente moldado e desenhado de acordo com o projeto de engenharia da peça.

Injection Moulds

The injection moulds are produced thorough machining processes of high precision (via CAM - computer aided manufacturing). Its composite is perfectly moulded and designed according to the part's engeneering process.

Injection Moulds

O primeiro processo na fabricação das peças microfundidas é a injeção de cera líquida em alta temperatura nas matrizes resfriadas. Tudo isto realizado em equipamentos de precisão de injeção e com os devidos controles de pressão e temperatura.

Wax Patterns

The first process in the manufacturing of investment cast parts is the high temperature liquid wax injection in the cooled matrices. This process is carried out in high precision injection equipment under careful control of pressure and temperature.

Wax Moulds

Cada uma das peças em cera rígida agora são acopladas e fundidas em um suporte de cera, formando então uma árvore com várias unidades acopladas. Esta será o suporte para receber os banhos das próximas etapas.

The Wax Tree

Each of the parts in rigid wax is now joined with and linked to a wax sprue forming a tree liked structure with the units put together, this structure will receive the slurry baths in the next steps.

The Wax Tree

Cada árvore de cera receberá um banho com uma lama cerâmica, devidamente desenvolvida para prover a aderência do estuco cerâmico da próxima etapa, formando então uma árvore de molde cerâmico.

Shell Building

Each of the wax trees will be covered with different ceramic slurry baths, especially developed, forming once hardened, a ceramic covering with the required structure and resistance.

Moulding

Nesta etapa a árvore cerâmica será colocada em autoclave onde ocorrerá a retirada da cera através do aquecimento com vapor. A cera eliminada será direcionada para um sistema de reaproveitamento, onde será devida filtrada e posteriormente reutilizada.

Dewaxing

In this particular step the wax tree with its ceramic cover shall be put into an autoclave where the wax removal from the mould will take place through steaming, creating therefore, a ceramic mould. The wax that runs out of the mould will be directed to a recovering system for later reuse.

Processo 1: Produção dos moldes de injeção.

Os moldes cerâmicos são levados a uma fornalha industrial que calcinará toda estrutura dos mesmos, internamente e externamente, a uma temperatura de aproximadamente 1.0000C. isto eliminará qualquer resíduo de cera e proverá mais resistência e rigidez para os moldes.

Burnout Preheating

The ceramic moulds are taken to a furnace at a temperature of about 1000 degrees Celsius, removing any wax left and providing the mould with the required resistance and stiffness.

Burnout Preheating

O projeto da peça a ser produzida determina exatamente o tipo de liga metálica a ser criada através da mistrura de metais específicos. Um controle de qualidade rigoroso durante todo o processo de fundição garante que  osciliações sejam corrigidas e a variação mantida mínima para todo o lote.

Molten Metal

The elaboration of the metal alloy follows strict specifications required by customers whose chemical composition is verified and assured during the investment casting process through a spectrometer.

Metal alloy

O projeto da peça a ser produzida determina exatamente o tipo de liga metálica a ser criada através da mistrura de metais específicos. Um controle de qualidade rigoroso durante todo o processo de fundição garante que  osciliações sejam corrigidas e a variação mantida mínima para todo o lote.

Casting CGP (counter gravity pouring process)

It's in this particular step that Fupresa's main quality differential is applied. The ceramic mould adequately heated is placed into a metal chamber putting the mould in contact with the liquid metal which will be aspired by vacuum (CGP - counter gravity pouring process) fulfilling the mould cavities forming the final parts.

Pouring CGP

Após resfriados totalmente, as árvores são submetidas à impactos controlados, estes deverão quebrar a cerâmica e liberar as peças metálicas. Câmaras de atritos com jatos de metais são realizados para a remoção completa da cerâmica.

Divesting

Once thoroughly cooled, the shell shall be submitted to controlled impacts, blasted,vibrated, breaking the ceramic shell in order to release the solid metal parts and remove the ceramic residues.

Divesting

O acabamento fino é realizado peça por peça, hora por máquinas automatizadas de usinagem (CNC), hora realizados manualmente por profissionais devidamente treinados. Outros acabamentos adicionais são realizados individualmente nesta etapa.

Machining

The finishing is done part by part, either by computer numeric control (cnc) machines or by other more more specific equipment or processes.

Machining

O acabamento fino é realizado peça por peça, hora por máquinas automatizadas de usinagem (CNC), hora realizados manualmente por profissionais devidamente treinados. Outros acabamentos adicionais são realizados individualmente nesta etapa.

Final inspection

After all the processes are finalized the parts are submitted one by one to a “poka-yoke” device where well trained professionals inspect the final product which will later be wrapped according customers specifications.

Final inspection

Project guide

An Investment casting guide

Fupresa has prepared a complete guide aimed at engeneering professionals. This guide provide them with technical information, definitions and concepts of very high value about the investment casting process and it's advantages and applications.

Investment casted parts as a substitute for:

forged and fondry

The greater the impact of machining cost over the final cost of forged or fondry products, the greater the advantage in the adoption of the CGP (counter gravity pouring process) manufacturing process.
As the CGP (counter gravity pouring process) process allows for extremely thin walls (from 1mm) it become viable the development of items with substantial weight reduction when compared to other possible processes of fondry or forging.
The freedom for designing products with complex shapes is another competitive advantage the CGP (counter gravity pouring process), because the conventional processes present several restrictions to the adoption of more complex geometrical shapes.

Welded and machined

Products obtained through welding of different metal components can be supplied with economical advantages when adopting the CGP (counter gravity pouring process) process if the welded product to be replaced by the investment casted product requires operations which may result in an increase in the final cost, such as machining or straightening.
Machining processes of steel bars with low machinability have been replaced with great success by the CGP (counter gravity pouring process) process.

Adding Value

  • Mechanical assembly

    Built of investment cast parts associated to components obtained by other technologies such as plastic, rubber,nuts and bolts.

  • Mechanical finishing

    Such as straightening, coinage, machining,frequently used in order to meet the needs of the dimensional or geometrical specifications, which cannot be obtained directly in the investment cast part.

  • Heat treatment

    Technologies of metallurgical finishing, such as heat treatment under controlled atmosphere and induction hardening, are internally available.

  • Electroplating treatment

    Electroplating treatment are also available through subcontract with qualified and ISO-9000 certified suppliers.

PROCESS ADVANTAGES

  • Better yield of molten metal
  • Substantial energy saving process
  • Higher number of parts per mold
  • PARTS WITH GREATER RESISTANCE AND DURABILITY
  • TOTAL FREEDOM IN THE PROJECT OF THE PART
  • Substancially lower cost
  • Much better quality