Design Considerations

Cast Holes

The mould material used by the Sylatech casting process is applied as a slurry and is easily removed by water jets. This enables fine through holes of up to 0.8mm in diameter to be cast.

Long through holes may be cast if crossholes are provided to support the mould core during casting.

diagram of cast holes with supports using slots
Examples of support using a slot
diagram of cast holes with support using side hole
Examples of support using a side hole
casting with a maze of holes
This casting is a maze of holes. Its perfect surface is due to easy mould removal

Blind Holes

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

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

Threads

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.

Holes can also be cast which are suitable for self-tapping screws.

cast holes diagram of support using a counter bore
Examples of support using a counter bore
blue and white lightbulb icon

To reduce cost and improve accuracy a cast counter bore can be used in through hole applications where a tight tolerance is rarely needed over the full length.

Drill starts can be incorporated to aid drilling in cases where blind holes may be too long to cast.

Where a component is to be clamped to a shaft, a clamping slot can be cast, rather than machined. To make reaming of a through hole easier and more accurate a removable support bridge should be included.

Draft Angles

The Sylatech casting process does not normally require draft angles as the wax has a 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.

Sylatech Design Guide

Design Guide v2
Download the Design Guide

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