HOW WE WORK

WE DEVELOP YOUR PROJECT FROM DESIGN
TO FINISHED PRODUCT

From the idea to the realization of the detail. Microfound is a partner who co-designs the component with the customer, so that the project can exploit the full potential of micro-fusion technology.

ENGINEERING

Microfound works in close collaboration with the customer to analyse the technical specifications of the component and its end use.

The initial project is industrialized through Cast Engineering, to obtain the best results from the casting process.

3D technologies favour the exchange of information and, in the design phase, can be used for component prototyping and casting simulations, ensuring maximum reliability in the analysis of casting problems.

CAST AND REVERSE ENGINEERING

  • With Cast Engineering, we optimize the geometry of the object in order to obtain the casting of a component with high quality standards and cutting-edge design aesthetic characteristics.

CASTING SIMULATION

  • The casting simulation highlights possible anomalies in the initial feasibility phase, in order to define the optimal parameters and obtain the best quality-price ratio.

  • Through this activity, you have a preview of what will happen during the casting, to optimize the process and visualize the hot spots, porosities and trapped gases. In this way, you can make immediate corrections by reducing the sampling phases.

PROTOTYPING

  • A latest generation 3D printer allows you to obtain the wax model, starting from the 3D CAD drawing, without building the mould. The model thus obtained is compatible with the normal casting process.

  • Prototypes, pre-series and small cast batches in any type of steel are ready in a few weeks. In a short time, the customer can proceed with machine tests, mechanical tests and product validation before series production.

  • Prototypes have excellent surface roughness, like a normal series production.

MATERIALS AND TOLERANCES

The choice of material to use for the creation of a component can be made from a very vast range of steels and special alloys, both corresponding to international standards and made specifically for particular customer needs. The most commonly used steel alloys are: case-hardening, tempering, nitriding, martensitic, austenitic, ferritic and precipitation-hardened stainless steels.

FOUNDRY

LOST-WAX PRECISION CASTING:
THE PRODUCTION PROCESS

MOULD In agreement with its customers, Microfound manages the design and construction of the carved aluminium mould. The moulds are stored in protected warehouses with automatic recall. WAX MODELS PRINT Les modèles en cire sont imprimés par des presses à injection. ASSEMBLY AND CONSTRUCTION OF THE BUNCH I particolari in cera estratti dagli stampi, dopo un periodo di stagionatura, sono montati manualmente su steli (serviranno da canali di alimentazione) a formare i grappoli. CERAMIC COATING Attraverso ripetute immersioni dei grappoli in soluzioni ceramiche e successiva aspersione con sabbie, si formano i gusci ceramici composti da diversi strati di rivestimento, capaci di resistere alla colata del metallo fuso. Dopo la formazione di ogni strato, i grappoli sostano in appositi ambienti a temperatura e umidità controllata, fino all’ottimale asciugatura. WAX EVACUATION Dopo l’essiccazione, il grappolo passa in fonderia dove la cera contenuta nei gusci ceramici è sciolta ed estratta completamente in un’autoclave. Si ottiene così la forma vuota che sarà riempita dal metallo fuso. FIRING OF THE SHELL La coque céramique vide passe dans un four de préchauffage, où a lieu la cuisson qui permet le frittage du revêtement céramique qui résistera au métal fondu. CASTING Il metallo fuso in un forno a induzione è colato nella forma pre riscaldata dove solidifica raffreddandosi. SHAKEOUT Il materiale refrattario è rimosso meccanicamente per liberare i particolari fusi. FINISHING I pezzi sono separati dai canali di alimentazione tramite dischi e nastri abrasivi. Seguono le operazioni di sbavatura, finitura, eventuali trattamenti termici e lavorazioni meccaniche. QUALITY CONTROL Before being sent to the customer, the parts are checked and tested according to the agreed specifications, with instruments for dimensional analysis, chemical analysis, hardness analysis, radiographic analysis, liquid penetrants, magnetoscopy and metallographic analysis.

HEAT TREATMENT

Heat treatment is an important phase of the process: it is chosen based on the type of steel and depending on the final use and the mechanical properties of the part. Heat treatments are carried out externally, through recognized partner companies capable of continuous technical support.

MECHANICAL PROCESSING

Microfound relies on a network of specialized workshops, to carry out mechanical processes and provide a finished product, in compliance with the specifications and guaranteeing high quality standards.

SURFACE TREATMENTS

Microfound has an internal service specialized in surface treatments and finishes of metals and investment castings. The service is managed by the MFinishing line.

HEAT TREATMENT

Heat treatment is an important phase of the process: it is chosen based on the type of steel and depending on the final use and the mechanical properties of the part. Heat treatments are carried out externally, through recognized partner companies capable of continuous technical support.

MECHANICAL PROCESSING

Microfound relies on a network of specialized workshops, to carry out mechanical processes and provide a finished product, in compliance with the specifications and guaranteeing high quality standards.

SURFACE TREATMENTS

Microfound has an internal service specialized in surface treatments and finishes of metals and investment castings.

The service is managed by the MFinishing line.

QUALITY CONTROL

Microfound carries out rigorous quality controls at every stage of production. From project reviews to final quality checks: each step is documented and batch traceability is always guaranteed. Our Technical and Quality Team uses a laboratory equipped for non-destructive testing and to guarantee the conformity of the metallurgical, metrological, physical and chemical composition properties of the product, through tools such as:

  • Radioscopy booth

  • Liquid penetrant examination system

  • Magnetoscope

  • Durometer

  • Micro durometer

  • 3D scanning tool

  • CMM

The laboratory is integrated into the offices, to facilitate the passage of information between the various departments.