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The Graphicast precision casting process uses graphite molds to produce net and
near net shape parts in ZA-12 zinc alloy. It is an economical alternative to sand,
die, and investment casting; machining; and, in some cases, plastic injection molding
for production quantities of 300 to 20,000 parts per year.
The exceptional machinability of graphite dramatically shortens the time needed
to produce molds. In fact, the machining of graphite molds often takes weeks less
than the machining of die casting molds.
And, the high accuracy and exceptional surface finish of parts cast in graphite molds
virtually eliminate the additional finishing steps required with other casting techniques.
This further reduces the total time from design to production.
The economic advantages of the Graphicast process lie in lower total acquisition
costs as a result of reduced tooling costs, the reduction or elimination of
secondary machining operations, and shorter time to market.
Parts produced through the Graphicast process have dramatically lower total cost
per part and significantly better finishes and appearance than machined sand
castings.
Compared to die casting, the Graphicast process has much lower tooling costs which
can be amortized over shorter production runs. Graphicast castings also have a
more homogeneous structure than die cast parts.
The Graphicast process produces parts with accuracies and surface finishes as
good or better than investment cast parts, but with a much lower cost per part.
(Based on production quantities of 300 to 20,000 parts per year)
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Precision
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Finish
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Tooling Cost
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Cost per Part
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Graphite Mold Process
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High
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High
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Low
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Medium
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Machining from Bar Stock
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High
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High
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Low
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High
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Sand Castings/Machined
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Low/High
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Low
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Low
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High
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Die Casting
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High
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High
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High
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Low
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Investment Casting
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Medium
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Medium
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Low
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High
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Injection Molding
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High
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High
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High
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Low
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