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The Replicast® process
The polystyrene replica
The Replicast® process consists in making from a metallic die a high-density polystyrene pattern (replica) identical to the part to be produced.
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Several replicas may be glued together to get a cluster (assembly).
Consequently complex-shaped parts may be easily produced by assembling simple elements. |
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The casting of the part
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The hollow ceramic shell (exact replica of the part to be cast) is mechanically settled in a box containing vibrated loose sand and maintained under partial vacuum during the casting.
The casting of the parts may be carried out by classical way of gravity pouring or by the LPSC counter-gravity process (“L+R” process). |
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The coating of the replica
The high-density polystyrene replica (or the cluster) is coated by several ceramic layers. These coatings are made from successive dipping, draining and stucco-applying operations. At the end, a self-supporting ceramic shell is made up.
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The burning
The replica is burnt in a high temperature furnace. In the meantime, the hollow ceramic shell gets further mechanical resistance.
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