The second chapter of the white area 2.5 manual molding process

First of all, let's talk about the scope of application of handmade appearance:Enterprises with small production batches, many batches, small annual production, a wide variety of castings and simple structureGating system (including pouring cup and runner)Single piece test note.

So, what is the process of manual molding in the white area?

Typing→ stereotype → blanking → cutting → manual tool making → cutting → bonding → polishing and repairing

2.5.1 Preparation before manual molding

1.Make the required tools


Wide-seat square ruler


round nail

painting needle

claw hammer

utility knife

Hot glue gun, glue stick

resistance wire

There are also hand tools.

Requirements for tools:

The size of the ruler is accurate (comparison of several rulers)

The marking lines on both sides of the ruler are the same (the line drawn by turning the ruler, and the coincidence shall prevail)

The square is indeed vertical (the square is flipped to draw a vertical line., subject to coincidence)

2.Template (PS plate, aluminum plate) specifications

The thickness is0.3mm, the area can be selected according to the needs (also can be used for splicing). The template is mainly used to be easy to cut and not easy to deform. We are now used to this aluminum foil plate.

1.The purchase of foam board

Handmade appearance of the plate is generally usedEPS raw materials, its advantage is low price, gas is small, its disadvantage is to make the casting carbon.

Purchase of foam requirements:

Density: The density is16Kg-18Kg/m3

Low density, reduced resistance to bending, easy to make shape deformation.

The high density of its foam gas volume increases, easy to make the casting porosity defects.


When the foam board is wet and cut, it is easy to cause the surface finish of the pattern is not high and the shape is deformed, and the size is distorted. Therefore, if the foam is wet after cutting, it needs to be cut into the required pieces and dried in the drying room, and then the corresponding pattern is made.


Cut the inside of the foam and its continuity should be very good, as far as possible without any gaps and potholes. See Figure1、2. Foams with poor surface continuity will affect the surface quality of castings and even cause casting defects.

Figure1 Continuity difference diagram2    Good continuity

2.5.2 Process flow of manual molding

1.Casting Parting

Casting parting is the first step of manual ink injection, but also the most critical step, the specific implementation steps are:

According to the drawing processing requirements to simplify the casting structure, the more complex the casting structure, the greater the need for parting, the greater the difficulty of manual molding.

Determine the number of parting. There are many ways to type the number and shape, and the general principles are: saving time, saving board, saving foam, and using less glue. As far as possible to reduce the number of parting, the number of cutting, reduce the difficulty of cutting, improve the accuracy of bonding assembly, reduce the use of adhesive glue (because the gas volume of glue is several times that of ordinary foam).


The production of templates is called stereotype:


Spread the template on the workbench and fix it with round nails. According to the drawing, add the processing amount of each component, the shrinkage amount of benzene plate, the appropriate cutting loss amount, and reserve the bonding increase amount.

With art knife, compasses cutting plate, tear plate, a template is generallyTwo pieces.

Pat the template flat on the table with a ruler and tie holes at the edges.

Two templates clamp the foam block to cut the required pattern components. Fix with pins or thin iron nails.


The blanking shall be on the blanking platform (or cutting platform).

bunk on platform12mm high density board, paved on board12mmGlass plate, both sides of the cutting height adjustment rod, the adjustment rod has an insulating plate, tension spring and0.5mmNickel-chromium resistance wire. When in use, adjust the cutting resistance wire to be the same size at both ends, and generally add another size to the required size.1mmThe amount of cutting loss. Regulator shall be gradually increased from zero until test cutting with waste foam to see if it is the required height.

The use of density board is mainly not deformed by moisture, to the glass plate buffer.

When purchasing glass plates, pay attention:

① Both sides should be smaller than the table top, for example: the table top is1200mmX1200mm, the glass plate specification shall be1200mmX1000mm, Its purpose is to be smaller than the tension spring, and it will not cause foam waste when peeling.

② Ensure the flatness of the board surface, no wavy lines, and avoid uneven height and size of the cut material.

Specific steps of blanking

① The foam skin shall be removed before formal cutting (I. e. no skin shall be taken up and down on any material). When the skin is removed, the bottom and two adjacent sides shall be selected, and the three planes shall be formed90°. Go to the outer skin to find90°, should be placed on the platform, and foam block material90° (or pad the block with waste foam90°) cutting.

Adjust the height of the cutting resistance wire and lower the square material required for each template. Each shape of material must be cut into square materials, cut into square materials as far as possible to achieve six sides, that is, each corner90°。


The cutting process is also carried out on the cutting table. The two templates are clamped against the foam square and fixed with pins or fine iron nails.
For the short distance of the foam can be directly cut on the cutting table, if the distance is longer, it can also be cut by two people.

When cutting the shape should pay attention:


① The cutting shall be done at one go, at a constant speed, without stopping, without cutting twice, and the template and cutting resistance wire shall be kept forever.90°。

Cut the through hole, penetrate the through wire (with hook wire) with resistance wire through the foam, and stick the template for cutting (the cut through hole is generally not more200mm, so as not to misfit the size of the central part).

The most important thing about manual molding is a feel. Generally, there are two kinds of cutting:

Use20mmX20mmX150mm(200mm) the square material is cut into φ20Cylinder.

Use100mmX100mmX100mm square material cut100mmX50mm round table.

5.Production of manual molding tooling

In the previous step, only some regular models can be obtained, but there are many special and complex structures for a casting, which are difficult to obtain by cutting with the lower template. For example, special structures such as cutting blind holes and grooves cannot be obtained by using ordinary manual cutting tables. At this time, manual molding tooling needs to be made for cutting.

For hand tools10mm thick insulation board, cut into two strips of square plates, used8mm-10mm stud fixing. Will1.0mmThe iron-chromium-aluminum resistance wire is folded into the size of the required shape with pointed-nose pliers, and fixed with an insulating plate clamp.

What you need to pay attention to when making is:Pay attention to the amount of cutting and burning,When making shapes, pay attention to fixing when cutting,Straighten the linear resistance wire with a claw hammer.

6.cut out

After the manual tool is made, it can be cut by powering on. When cutting, the main hand tools are limited, so that the cutting is relatively stable, generally there are two kinds, one is to fix the template on the white mold, and the other is to close to the shape of the white mold. When cutting, pay attention to the fixed nails will not interfere with the insulation board.


After cutting the components of the white mold, they can be bonded together. Two kinds of hot glue and cold glue are mainly used for bonding. Hot glue is generally used for small-area bonding, and cold glue is used for large-area bonding. The specific selection will be explained in the following courses. No matter hot glue or cold glue is used for bonding, the most important thing is to coat the gaps of the components tightly and not leave any gaps.

8.Grinding repair

After the white mold is bonded and combined, polish the white mold with a finer sandpaper. The main purpose of polishing the white mold is to cut the small surface of the white mold, and to prevent the fire resistance of the coating from being affected after cleaning. Fine sandpaper can also be used to grind out the small rounded corners of the casting.

For the hot marks generated during cutting, or the local continuity of the white mold is not good, damaged, etc., you can use glue to paste and repair it, or use double-sided adhesive tape paper, newspaper, etc.

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