A requirement for automated injection of wax patterns is the ability to make defect free patterns. MPI has collaborated with two US foundries in 2015 to demonstrate how quality dies combined with the proper application of process controls can eliminate common wax injection defects. Demonstrated results have shown significant reduction of scrap in the wax room, increased throughput and higher casting yields. With a die that now runs defect free the ability to automate injection exists. Automated assembly with little to no inspection also requires defect free injection. To continue with the foundation formed in the past papers focused on defect reduction of wax pattern making, this paper goes to the next phase of process improvement. Using commercial parts from a low volume order, we explore how to cost effectively fully automate injection and assembly. Again, MPI will collaborate with a foundry. Work performed as well as the results are shared.
Where applicable, the ICI Atlas of Wax Pattern Defects, REVISED 2ND Edition as well as the ICI Process Control course materials are referenced. Experience has demonstrated the automation of injection and assembly of wax patterns results in a significant increase in throughput. In this paper we will illustrate how this can be accomplished economically.