Seamless Composite Mass Casting
Manuplas are able to provide a “Seamless” Mass casting solution – Manucast™ - as an alternative to the process of laminating individual mass produced modelling boards. Unlike the traditional process of laminating modelling boards, Manucast™ is a seamless production process enabling it to deliver a considerable number of benefits in terms of both cost and quality over these traditional methods.
- No joints or laminations
- Replicates typical modelling/tooling board properties
- Material waste minimised
- CNC machining time significantly reduced
- Good dimensional stability
- Low shrinkage
- Single pouring process
Manuplas currently have 2 polyurethane based formulations available. Manucast™ CPUB750 and CPUT1650. The first being for general purpose applications replicating the capabilities of a 0.7 – 0.8SG modelling board.
The second is for performance critical applications replicating the capabilities of 1.6-1.8SG tooling board.
Currently Underdevelopment is Manucast™ Epoxy - a mass cast pre-preg solution.
How the process works:
- Produce a cavity. This can be in the form of a simple box or to maximise the benefits of the process we utilise a “Lost Mould Process” type. This is the machining of EPS to produce a cavity slightly larger than the required dimensions of the finished product. The closer the form of the cavity is to the finished product, the lower the material waste is and the quicker the machining time. This cavity can either be produced in-house by Manuplas or supplied direct by the customer.
- Mass Cast the pre-prepared box/cavity in a single pouring process.
- Release the Mass Cast billet from the cavity. If no machining services are required, then the billet is best shipped to the customer in the cavity to give it better protection during transit.
- Post Cure of the billet prior to machining. (This service is optional depending on specific customer requirements).
We can provide our Manucast™ Mass Casting capabilities as a stand-alone service to produce a ‘billet’ that our clients then use in further processing or we can provide a ‘one-stop-solution’ right through to final, low volume manufacture of finished parts. Our clients have the choice about which of these services they ask us to provide and we have the flexibility and capabilities to tailor what we deliver to your needs.
To find out more about how we may be able to work with you as a contract composite manufacturing partner, please call us on 01752 771740 or send us a brief outline of your requirements using our Contact form.