Harmony Castings

V-Process Casting

Final Design to Casting in Just Two Weeks

V-Process Casting is the most efficient way to produce castings of all sizes and shapes.

Step 1:  The pattern (with vent holes) is placed on a hollow carrier plate.

Step 2:  A heater softens the .003” to .008” plastic film. Plastic has good elasticity and a high deformation ratio.

Step 3:  Softened film drapes over the pattern with 200 to 400 mm Hg vacuum acting through the pattern vents to draw it tightly around the pattern.

Step 4:  The flask is placed on the film-coated pattern. Flask walls are also a vacuum chamber with the outlet shown at right.

Step 5:  The flask is filled with dry, unbonded sand. A slight vibration compacts sand to maximum bulk density.

Step 6:  A sprue cup is formed and the mold surface leveled. The back of the mold is covered with unheated plastic film.

Step 7:  Vacuum is applied to the flask. Atmospheric pressure then hardens the sand. The vacuum is released, pressurized air is introduced into the carrier and the mold is stripped.

Step 8:  The cope and drag assembly forms a plastic-lined cavity. During pouring, molds are kept under vacuum.

Step 9:  After cooling, the vacuum is released and free-flowing sand drops away leaving a clean casting with no sand lumps. The sand is cooled for reuse.

V-Process Sequence

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Aluminum Castings: Process Comparisons

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V-Process Aluminum Casting Advantages

View the V-Process PDF | View the V-Process Video

Aluminum Castings: Process Comparisons

Process Typical Size Range Tolerances Surface Finish Min. Draft Required Min. Section Thickness Typical Order Quantities Typical Tooling Costs Nominal Lead Times
V-Process Castings Up to 150 lbs± 0.10" for the first inch, then add ± .002"per inch. Add a max .020 across parting line 125-150 RMSNone.125" All $3,000 to $14,000Samples: 2 to 6 weeks
Production: 2 to 6 weeks after approval
Sand Castings Ounces to tons ± 1/32" to 6", then add ± .003" per inch. Add a ± .020" to .090" across parting line. 200-550 RMS1 to 5 degrees.25" All$800 to $4,000 Samples: 2 to 6 weeks
Production: 2 to 6 weeks after approval
Investment (Lost Wax) Castings Ounces to 20 lbs ± .003" to 1/4", ± .004" to 1/2", ± .005" to 3",then add ± .003" per inch. 63-125 RMS None .060" Under 1000 $3,000 to $20,000 Samples: 8 to 10 weeks
Production: 5 to 12 weeks after approval
Permanent Mold Castings Ounces to 100 lbs ± 0.15" to 1", then add ± .002" per inch. Add ± .010" to .030" across parting line. 150-300 RMS 2 to 5 degrees .1875" 500+ $5,000 to $25,000 Samples: 8 to 20 weeks
Production: 10 to 12 weeks after approval
Plaster Mold Castings Ounces to 50 lbs ± .005" to 2", then add ± .002" per inch. Add ± .010" across the parting line. 63-125 RMS 1/2 to 2 degrees .070" Prototypes up to 250 $3,000 to $15,000 Samples: 2 to 10 weeks
Production: 4 to 8 weeks after approval
Die Castings Ounces to 15 lbs ± .002" per inch. Add ± .015" across parting line. 32-63 RMS 1 to 3 degrees .030" to .060" 2500+ $10,000 to $100,000 Samples: 12 to 22 weeks
Production: 8 to 14 weeks after approval
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