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Micro Metalsmiths - Brass Castings

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Since 1964 the Micro Metalsmiths' precision investment casting process still leads the field in the production of small, finely detailed and often very complex aluminium castings and brass castings.

Having established a reputation for world excellence in engineering and the production of precision investment cast components, Micro Metalsmiths' aluminium castings and brass castings are manufactured under a BS EN ISO 9001 approved quality system.

A major advantage to all our customers is the provision of a full range of in-house facilities including CNC machining of our precision investment cast aluminium and brass castings. As a result, customers' needs can be met with a greater degree of flexibility. Any customer who has a need for rapid prototyping will find that the latest techniques are available.

Micro Metalsmiths is able to offer its own:

  • project management
  • design department
  • investment foundry
  • machine shop
  • assembly shop
  • microwave engineering department

At the present time Micro Metalsmiths can claim to be the only company in the European Union with all these facilities under one roof.

Request Quote / Contact Micro Metalsmiths

Design Guide

Micro Metalsmiths continues to develop its process so as to meet ever more exacting market challenges.

If you have an aspect not covered by this guide, please contact our Liaison Engineers who can up-date you on our latest capability and assist in the design of your components.

For over thirty years Micro Metalsmiths has refined its techniques for excellence in the production of copper and aluminium alloy investment castings.

Micro Metalsmiths has combined its impressive investment casting technology with best practice CNC machining so allowing many of the constraints placed on engineering design to be overcome. This is all carried out within a BSI accredited ISO 9001 Quality System.

Why use the MM casting process:

  • Reduce overall costs by Designing for Manufacture: simplify an assembly by combining a number of parts: eliminate joining processes: reduce the part count whilst improving the integrity of the finished product.
  • Reduce time to market through use of Rapid Prototyping technology and obtain casting, machining, assembly and packaging from one source. Finished metal parts are deliverable from concept in under four weeks.
  • Design flexibility, with quick modifications to tooling that costs 90% less than for a pressure die casting, whilst maintaining economic batch quantities of up to 500,000 parts per annum.
  • High quality finish, detail and specification.

What the MM casting process can deliver:

  • Thin walls as fine as 0.2 mm (0.008"), typically 1-3 mm (0.04" - 0.12").
  • Light weight components, weighing as little as 1g (0.04 oz.) can be produced using techniques to minimise material usage whilst retaining component integrity.
  • Maximum size of 190 mm x 160 mm x 160 mm (8" x 6" x 6"). A length of 250 mm (10") is possible providing no other dimension exceeds 100mm (4").
  • Complex detail on internal and external features.
  • Superfine surfaces with 0.8 micrometres (32 micro inches) being the "as cast" finish.
  • Zero draft angle

Wall Sections

Thin walls and uniform wall thickness always produce superior castings with minimum porosity, distortion and tolerance spreading. View Suggested Wall Thickness and Tolerance Charts

Casting Tolerances

Tolerances depend on the geometry of each part, but the following tolerances are suggested as a guide to designers. Learn more/view charts

Cast Holes

The mould material used by the MM casting process is applied as a slurry and is easily removed by water jets. This enables fine through holes to be cast. Length to diameter ratios can vary upwards from 4:1 dependent on diameter.

Blind holes can be cast provided the depth to diameter ratios do not exceed 3:1. Holes of under 0.5 mm (0.020") diameter are often cast.

Elongated holes can easily be cast allowing the take up of tolerances within an assembly.

Threads are best not cast but provision of a hexagonal cavity around a bolt hole allows the use of a captive nut or bolt, removing the need to tap a hole.

Also holes can be cast which are suitable for self tapping screws.

View photos and drawings

Draft Angles

The MM casting process does not normally require draft angles as the wax has relatively low injection pressure, is self lubricating and has minimal shrinkage.

However, if investment casting is being employed to develop a component, which may eventually be produced in very large quantities as a pressure die casting, then draft angles can be incorporated to simulate those which will eventually be needed.

Special Features

  • Soluble
  • Wax assembly
  • Cast gears and teeth

    Integrally cast rivets can be peened over to give an economic, strong and permanent joint.

View photos

Radii

Square corners are a feature of the MM casting process. Internal radii can be easily introduced to increase strength. An external 1 mm (0.04") radius is often useful on larger parts as it reduces any tendency of the mould material to crack on firing, however, square corners can be accommodated if required.

Surface Finishes

  • "As cast"
  • Chip rumbling
  • Automatic grit blasting
  • Bead blasting
  • Glass bead blasting
  • Special surface effects

learn more about surface finishes

Integrated Labelling

It is possible to include many types of permanent product identification which can eliminate further need for labelling. Logos and text may be produced with minimum cost if the design ensures that detail is in the line of draw of the wax from its die.

Ideally, cast labels should use raised lettering on the casting face (engraved into the wax tool). Where such information must be below a functional surface, it can be sited on a pad sunk into the cast face.

Preferred depth of engraving: 0.25 mm - 0.50 mm (0.010" - 0.020").

Applied surface treatments

The following treatments can be applied:

  • Alocrom1200 / Iridite / Chromate Conversion
  • Anodising
  • Plating
  • Hipping (Hot Isostatic Pressing)
  • Impregnation
  • Paint

learn more about applied surface treatments

Heat treatments

Various heat treatments can be applied to hardened components. This is carried out generally to aid subsequent machining and enhance component stability.

Suffixes to the material grade are used to denote the heat treatment carried out. View chart of UK and equivalent USA and EN suffixes

Tooling

A tool body is made from aluminium. Moving parts in the tool are produced in brass or steel to prolong their life and maintain accuracy. Design changes can be made quickly, particularly when material is added to the component, as metal is removed from the die. More info ...

Machining

The machining of castings requires a different approach to the machining of wrought metal components. Castings are never totally flat, square, round or straight. A secondary datum system may be required to define the machining requirements. More info ...

Supply of Design Information

Quality Assurance

Micro Metalsmiths is approved to ISO 9001 BSI Certificate Number: Q6118.

Case Studies: Precision Investment Casting Products

Metal Specifications

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